A method of designing a sliver support, a sliver support structure and a sliver binding machine

Abstract

This application relates to a yarn bundle support design method, a yarn bundle support structure, and a yarn binding machine, belonging to the field of optical fiber and cable manufacturing technology. The yarn bundle support design method includes: selecting the theoretical length of the free section of the brush based on the yarn bundle's ultimate compression and the preset length margin of the brush's implanted section; obtaining the theoretical stiffness of the brush bristles based on the theoretical length of the free section and a first set of brush bristle design parameters; determining the theoretical density of the brush bristles based on the theoretical stiffness of the brush bristles, the target value of yarn friction, and a second set of brush bristle design parameters; and obtaining the yarn bundle support force based on the theoretical density of the brush bristles, the theoretical length of the free section, and a third set of brush bristle design parameters, and determining whether the yarn bundle support force is greater than the target support force of the yarn bundle. The brush provides lateral constraint to the yarn bundle, providing a precise tension adjustment mechanism, eliminating instantaneous tensile stress during high-speed yarn unwinding, and achieving dynamic tension balance.

Description

Technical Field

[0001] This application relates to the field of optical fiber and cable manufacturing technology, and in particular to a yarn bundle support design method, yarn bundle support structure and yarn binding machine. Background Technology

[0002] In the optical fiber communication industry, the fiber optic bundling process is a crucial step in ensuring the transmission performance and mechanical reliability of optical fiber products. The bundling quality directly affects the attenuation characteristics of the optical fiber, while excessive bundling tension can cause micro-bending loss in the fiber, leading to a significant increase in signal attenuation and consequently reducing network transmission efficiency and stability.

[0003] Therefore, the tension of optical fibers must be strictly controlled during manufacturing to avoid excessive attenuation. While current mainstream active yarn unwinding equipment can automate yarn unwinding, it cannot achieve a truly "zero tension" state. When these devices operate at high speeds, the yarn tension is difficult to dynamically balance, often resulting in the optical fiber experiencing instantaneous tensile stress.

[0004] In summary, the relevant technologies have an irreconcilable problem in zero-tension yarn release, which has become a core technological obstacle restricting the upgrading of the optical fiber industry chain. Summary of the Invention

[0005] This application provides a yarn bundle support design method, a yarn bundle support structure, and a yarn binding machine to solve the problem that the zero-tension yarn release in related technologies is irreconcilable and restricts the development of the optical fiber industry.

[0006] In a first aspect, a yarn bundle support design method is provided, comprising: selecting the theoretical length of the free segment of the brush based on the yarn bundle's ultimate compression and a preset length margin of the implanted segment of the brush; the brush includes a handle and bristles, the bristles including an implanted segment embedded in the handle and a remaining free segment located outside the handle; obtaining the theoretical stiffness of the bristles based on the theoretical length of the free segment and a first bristle design parameter; determining the theoretical density of the bristles based on the theoretical stiffness of the bristles, a target value of yarn friction, and a second bristle design parameter; obtaining the yarn bundle support force based on the theoretical density of the bristles, the theoretical length of the free segment, and a third bristle design parameter, and determining whether the yarn bundle support force is greater than the target support force of the yarn bundle; if so, designing the brush of the yarn bundle support device using the theoretical density of the bristles and the theoretical length of the free segment as design parameters; otherwise, re-selecting the theoretical length of the free segment of the brush.

[0007] In some embodiments, the theoretical length of the free segment of the brush is screened based on the ultimate compression of the yarn bundle and the preset length margin of the implanted segment, including: summing the ultimate compression of the yarn bundle and the preset length margin of the implanted segment to obtain a critical value; using the critical value as the minimum value to determine the range of values ​​for the theoretical length of the free segment; and selecting a value from the range as the theoretical length of the free segment.

[0008] In some embodiments, when assigning a value to the theoretical length of the free segment within the range of values, the value is selected according to a rule from small to large.

[0009] In some embodiments, before determining the theoretical bristle density based on the bristle theoretical stiffness, the target value of yarn friction, and the second bristle design parameters, the method further includes: obtaining the mapping relationship between the upper limit diameter of the yarn spool and the yarn release friction to confirm the upper limit value of the yarn friction; and confirming the target value of the yarn friction based on the upper limit value of the yarn friction.

[0010] In some embodiments, the first bristle design parameters include: the moment of inertia of the bristle cross-section and the bristle elastic modulus.

[0011] In some embodiments, the second bristle design parameters include: bristle friction coefficient, bristle compression, yarn diameter, and width of a single row of bristles.

[0012] In some embodiments, the third bristle design parameters include: single-row bristle contact area and average bristle compression.

[0013] In some embodiments, the distance between the yarn take-up points is adjusted based on the upper limit diameter of the yarn bundle so that the yarn release meets the yarn take-up design requirements.

[0014] In a second aspect, a yarn ball support structure is provided, which is made using the yarn ball support design method described in the first aspect above. The yarn ball support structure is used to be installed on a yarn tying machine and includes a brush. The brush includes a handle and bristles. Multiple handles are provided and distributed around the yarn bobbin shaft. The bristles are connected to the handles and a portion of the bristles is embedded in the handles, while the remaining portion extends toward the yarn bobbin shaft for contact with the yarn ball.

[0015] Thirdly, a yarn binding machine is provided, comprising: a yarn bobbin shaft, which is provided in multiple sets, each set of the yarn bobbin shaft having two; and the yarn ball support structure described in the second aspect, the yarn ball support structure being arranged along the circumference of the yarn bobbin shaft.

[0016] The beneficial effects of the technical solution provided in this application include: This application provides a yarn ball support design method, a yarn ball support structure, and a yarn tying machine. By accurately obtaining the theoretical length, theoretical stiffness, theoretical length of the free segment, and theoretical density of the brush bristles, and dynamically adjusting the theoretical length of the free segment and the actual density of the brush bristles based on the target support force of the yarn ball, a brush is designed. The brush is then used to provide lateral constraints for the yarn ball and to provide a precise tension adjustment mechanism, thereby eliminating instantaneous tensile stress during high-speed yarn unwinding and achieving dynamic tension balance. Attached Figure Description

[0017] To more clearly illustrate the technical solutions in the embodiments of this application, the accompanying drawings used in the description of the embodiments will be briefly introduced below. Obviously, the accompanying drawings described below are only some embodiments of this application. For those skilled in the art, other drawings can be obtained based on these drawings without creative effort.

[0018] Figure 1 This is a schematic diagram of the overall structure provided for an embodiment of this application; Figure 2 A schematic diagram provided for an embodiment of this application to illustrate the connection state between the yarn ball support structure and the yarn bobbin shaft; Figure 3 This is a schematic diagram illustrating the yarn support structure provided in an embodiment of this application.

[0019] In the diagram: 1. Yarn binding machine; 2. Yarn bobbin shaft; 3. Yarn ball support structure; 4. Brush handle; 5. Brush bristles; 6. Connecting rod; 7. Guide wheel. Detailed Implementation

[0020] To make the objectives, technical solutions, and advantages of the embodiments of this application clearer, the technical solutions of the embodiments of this application will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of this application, not all embodiments. Based on the embodiments of this application, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of this application.

[0021] Example 1 This application provides a yarn bundle support design method, which can solve the problem of irreconcilable zero-tension yarn release in related technologies, which restricts the development of the optical fiber industry.

[0022] Reference Figure 1-3 A yarn ball support design method, comprising: Step 1: Based on the yarn bundle's maximum compression and the preset length margin of the brush's implantation section, filter the theoretical length of the brush's free section. Filtering methods include, but are not limited to: summing the yarn bundle's maximum compression and the preset length margin of the implantation section to obtain a critical value; then, using the critical value as the minimum, determine the range of values ​​for the theoretical length of the free section; select a value from this range as the theoretical length of the free section. When assigning values ​​to the theoretical length of the free section within this range, it is important to follow an ascending order of value.

[0023] In this embodiment, the yarn ball gradually decreases in size as the yarn is released, causing changes in the contact area and compression between the brush and the yarn ball. The ultimate compression of the yarn ball specifically refers to the maximum distance the brush bristles 5 are compressed when in contact with the yarn ball at its maximum diameter. The ultimate compression of the yarn ball is the worst-case scenario that needs to be considered during the design process. The designed brush includes a handle 4 and brush bristles 5. The brush bristles 5 include an embedded section inside the handle 4 and a remaining free section outside the handle 4.

[0024] This application selects the most severe working condition for design because the bristle compression is greatest under these conditions. If the bristle length is insufficient at this point, it will directly lead to support failure and yarn collapse. The preset length margin of the implanted section is a safety space reserved to prevent the bristles 5 from completely detaching from the brush handle 4. The sum of these two is used as the critical value to ensure that the theoretical length of the free section meets the compression requirements at the maximum diameter of the yarn bundle while preventing the implanted section from completely detaching from the brush handle 4. The theoretical length of the free section is selected according to the rule of small to large, which ensures the minimum safety redundancy and avoids excessive support force and structural redundancy caused by excessive length. Thus, a precise balance between "micro-friction support" and "anti-yarn collapse" is maintained throughout the entire yarn unwinding process.

[0025] Step 2: Based on the theoretical length of the free segment and the first bristle design parameters, obtain the theoretical bristle stiffness. The first bristle design parameters include the moment of inertia of the bristle cross-section and the elastic modulus of the bristle. The theoretical bristle stiffness is obtained by the formula: k_bristle=(3×E×I) / L_bristle³; where k_bristle represents the theoretical bristle stiffness, E represents the elastic modulus of the bristle, I represents the moment of inertia of the bristle cross-section, L_bristle represents the theoretical length of the free segment, and E is obtained by looking up the bristle material properties in a table. I=(π×d_bristle)³ 4 ) / 64, d_bristle represents the diameter of a single bristle, and L_bristle is the target variable. The final value needs to be confirmed according to the design method to ensure that it meets the requirements.

[0026] For the most severe working conditions, stiffness calculations ensure that the bristles 5 will not collapse due to being too soft or tighten the yarn due to being too stiff under maximum compression. In addition, the theoretical length of the free segment is strictly taken as the input during the calculation to avoid excessive stiffness deviation due to length error. This provides accurate input for subsequent design and achieves a dynamic balance between "micro-friction support" and "anti-collapse yarn" throughout the yarn unwinding process.

[0027] Step 3: Based on the theoretical stiffness of the bristles, the target value of yarn friction, and the second bristle design parameters, determine the theoretical bristle density. The second bristle design parameters include: bristle friction coefficient, bristle compression, yarn diameter, and width of a single row of bristles. This step can be expressed by the formula: F_friction_yarn=μ×k_bristle×δ×ρ_row×(d_yarn×W_brush).

[0028] Here, F_friction_yarn represents the frictional force of a single yarn. Before determining the theoretical bristle density based on the theoretical stiffness of the bristles, the target value of the yarn frictional force, and the second bristle design parameters, it is necessary to: obtain the mapping relationship between the upper limit diameter of the yarn spool and the yarn feeding frictional force to confirm the upper limit value of the yarn frictional force; and confirm the target value of the yarn frictional force based on the upper limit value of the yarn frictional force. Obtaining the mapping relationship between the upper limit diameter of the yarn spool and the yarn feeding frictional force means that the frictional force needs to be as small as possible throughout the entire yarn feeding process. Therefore, our goal is that when the yarn spool diameter is at its maximum and the frictional force is also at its maximum, the frictional force of a single yarn does not exceed the target value of the yarn frictional force. The target value of the yarn frictional force is represented by F_friction_target, where F_friction_yarn ≤ F_friction_target. In this application, F_friction_target is preferably 0.001N. When the yarn spool diameter is at its maximum, the upper limit value of F_friction_yarn is 0.001N.

[0029] In addition, μ represents the bristle friction coefficient, δ represents the bristle compression, ρ_row represents the theoretical bristle density, d_yarn represents the yarn diameter, and W_brush represents the width of a single row of bristles. All of these are obtained by actually looking up tables, measuring, and calculating based on the properties of the bristles.

[0030] By precisely calculating the theoretical bristle density at the maximum diameter of the yarn bundle, the friction of a single yarn is ensured to be strictly ≤0.001N, thus achieving "zero tension" throughout the yarn unwinding process—meaning the yarn will not be pulled taut by the bristles, avoiding increased fiber attenuation. In simpler terms, at the maximum diameter of the yarn bundle, the required number of bristles is calculated to create sufficient gaps between them, allowing the yarn to glide effortlessly like gliding on smooth ice: it won't be "pulled" by the bristles, nor will it be "stuck" due to excessive bristle density. This maintains a precise balance of "micro-friction support" throughout the entire unwinding process, from the maximum diameter of the yarn bundle to its minimum.

[0031] Step 4: Based on the theoretical bristle density, the theoretical length of the free segment, and the third bristle design parameters, obtain the yarn ball support force and determine whether the yarn ball support force is greater than the target support force of the yarn ball. If so, use the theoretical bristle density and the theoretical length of the free segment as design parameters to design the brush of the yarn ball support device; otherwise, re-select the theoretical length of the free segment of the brush.

[0032] Specifically, the third bristle design parameters include: the contact area of ​​a single row of bristles and the average bristle compression. Based on the theoretical bristle density, the theoretical length of the free segment, and the third bristle design parameters, the yarn bundle support force is obtained, expressed by the formula: N_total=4×[k_bristle×ρ_row×A_row×δ_avg]. N_total represents the yarn bundle support force, k_bristle represents the theoretical bristle stiffness, ρ_row represents the theoretical bristle density, A_row represents the contact area of ​​a single row of bristles, which is obtained by A_row=W_brush×L_brush, where W_brush represents the width of a single row of bristles, L_brush represents the length of a single row of bristles, and δ_avg represents the average bristle compression.

[0033] The determination is made as to whether the yarn ball support force is greater than the target support force, denoted by N_total_min. This target support force is the minimum force required to prevent the outermost layer of the yarn ball from collapsing. This value needs to be estimated based on experience. For yarn balls supported by a mandrel, this force does not need to be large, mainly used to constrain the yarn rather than bear weight. In this embodiment, the target support force of the yarn ball is taken as 0.2N, and N_total = 4 × [k_bristle × ρ_row × A_row × δ_avg] ≥ 0.2N. If the calculated result meets the requirements, the theoretical bristle density and the theoretical length of the free section are used as design parameters to design the brush of the yarn ball support device; otherwise, the theoretical length of the free section of the brush is re-selected.

[0034] If N_total ≥ 0.2N, then the designed bristle length and density are effective. In this case, the bristle support is just enough to "support" the outermost layer of the yarn bundle, but not too much, otherwise it would increase tension like "squeezing the yarn too hard." If N_total < 0.2N, return to step one to increase the length of the free section to increase the support until the requirements are met. By accurately verifying whether the bristles can provide effective support, a precise balance is finally achieved where the yarn bundle is "stable and doesn't collapse or pull."

[0035] In this application, to further adapt to different specifications of optical fibers and avoid loose or excessively tight bundling, the distance between the yarn pick-up points is adjusted based on the upper limit diameter of the yarn bundle to ensure that the yarn release meets the yarn pick-up design requirements. In this embodiment, based on the yarn balloon theory and experimental verification, the minimum yarn pick-up point distance H_min should be greater than 2.5 to 4 times the maximum radius R_max of the yarn bobbin. That is, H_min ≈ k × R_max, where k is an empirical coefficient, typically ranging from 2.5 to 4.0. For low-speed, coarse-count yarns, k can take a smaller value, such as 2.5-3.0. For high-speed, fine-count yarns or those requiring high stability, k should take a larger value, such as 3.5-4.0. Based on the calculation basis of this invention, with a yarn bobbin diameter of Ø95mm, the minimum distance H_min between the yarn pick-up point and the yarn bobbin should be 3-4 times, between 142.5mm and 190mm.

[0036] Example 2 Reference Figure 1-3 This application provides a yarn ball support structure 3, manufactured using the yarn ball support design method of the first aspect described above. The yarn ball support structure 3 is used to be installed on a yarn tying machine 1. The yarn tying part of the yarn tying machine 1 used in this application embodiment is active, and the yarn feeding part is passive. The yarn ball support structure 3 includes a brush, which includes a brush handle 4 and brush bristles 5. Multiple brush handles 4 are provided and distributed around the yarn bobbin shaft 2. The brush bristles 5 are connected to the brush handles 4, and part of the brush bristles 5 are embedded in the brush handles 4, while the rest extend toward the yarn bobbin shaft 2 for contact with the yarn ball. The brush provides lateral constraint to the yarn ball and provides a precise tension adjustment mechanism, thereby eliminating instantaneous tensile stress during high-speed yarn feeding and achieving dynamic tension balance.

[0037] In another embodiment of this application, to facilitate the adjustment of the yarn picking point distance of the yarn ball, the yarn ball support structure 3 also includes a connecting rod 6 and a guide wheel 7. The connecting rod is connected to the brush handle 4, and the connecting rod is also provided with a waist-shaped hole. A bracket is connected to the guide wheel 7, and the bracket is movably connected in the waist-shaped hole. The guide wheel 7 is also connected to the bracket through a waist-shaped hole, so that the distance between the guide wheel 7 and the bracket, and between the bracket and the connecting rod can be adjusted. The convenient design of the waist-shaped hole allows for connection via a pin, which also allows for angle adjustment, making it convenient and reliable to use.

[0038] Example 3 Reference Figure 1-3This application provides a yarn tying machine, including a yarn bobbin shaft 2 and a yarn spool support structure 3. The yarn bobbin shaft 2 has multiple sets, specifically two sets, with two shafts in each set, allowing for the simultaneous feeding of up to four yarn spools. The yarn spool support structure 3 is arranged circumferentially along the yarn bobbin shaft 2 and includes a brush. Each brush includes a handle 4 and bristles 5. Multiple handles 4 are distributed around the yarn bobbin shaft 2. The bristles 5 are connected to the handles 4, with some bristles embedded within the handles and the remainder extending towards the yarn bobbin shaft 2 for contact with the yarn spools. The brush provides lateral constraint to the yarn spools, providing a precise tension adjustment mechanism, thereby eliminating instantaneous tensile stress during high-speed yarn feeding and achieving dynamic tension balance. To facilitate the adjustment of the yarn picking point distance, the yarn support structure 3 also includes a connecting rod 6 and a guide wheel 7. The connecting rod is connected to the brush handle 4, and the connecting rod is also provided with a waist-shaped hole. A bracket is connected to the guide wheel 7, and the bracket can be movably connected in the waist-shaped hole. The guide wheel 7 is also connected to the bracket through a waist-shaped hole, so that the distance between the guide wheel 7 and the bracket, and between the bracket and the connecting rod can be adjusted. The waist-shaped hole is conveniently designed, and the connection can be made by a pin, which also allows for angle adjustment.

[0039] In the description of this application, it should be noted that the terms "upper," "lower," etc., indicating the orientation or positional relationship are based on the orientation or positional relationship shown in the accompanying drawings, and are only for the convenience of describing this application and simplifying the description, and do not indicate or imply that the device or element referred to must have a specific orientation, or be constructed and operated in a specific orientation, and therefore should not be construed as a limitation of this application. Unless otherwise expressly specified and limited, the terms "installed," "connected," and "linked" should be interpreted broadly. For example, they can refer to a fixed connection, a detachable connection, or an integral connection; they can refer to a mechanical connection or an electrical connection; they can refer to a direct connection or an indirect connection through an intermediate medium; they can refer to the internal communication between two elements. For those skilled in the art, the specific meaning of the above terms in this application can be understood according to the specific circumstances.

[0040] It should be noted that in this application, relational terms such as "first" and "second" are used merely to distinguish one entity or operation from another, and do not necessarily require or imply any such actual relationship or order between these entities or operations. Furthermore, the terms "comprising," "including," or any other variations thereof are intended to cover non-exclusive inclusion, such that a process, method, article, or apparatus that comprises a list of elements includes not only those elements but also other elements not expressly listed, or elements inherent to such a process, method, article, or apparatus. Without further limitations, an element defined by the phrase "comprising one..." does not exclude the presence of other identical elements in the process, method, article, or apparatus that includes said element.

[0041] The above description is merely a specific embodiment of this application, enabling those skilled in the art to understand or implement this application. Various modifications to these embodiments will be readily apparent to those skilled in the art, and the general principles defined herein may be implemented in other embodiments without departing from the spirit or scope of this application. Therefore, this application is not to be limited to the embodiments shown herein, but is to be accorded the widest scope consistent with the principles and novel features claimed herein.

Claims

1. A yarn ball support design method, characterized in that, It includes Based on the maximum compression of the yarn bundle and the preset length margin of the implanted section of the brush, the theoretical length of the free section of the brush is selected; the brush includes a handle (4) and bristles (5), the bristles (5) include an implanted section implanted in the handle (4) and the remaining free section located outside the handle (4). Based on the theoretical length of the free segment and the first bristle design parameters, the theoretical stiffness of the bristles is obtained. The first bristle design parameters include: the moment of inertia of the bristle cross section and the elastic modulus of the bristles. Based on the theoretical stiffness of the bristles, the target value of yarn friction, and the second bristle design parameters, the theoretical density of the bristles is determined. The second bristle design parameters include: bristle friction coefficient, bristle compression, yarn diameter, and width of a single row of bristles. Based on the theoretical bristle density, the theoretical length of the free segment, and the third bristle design parameters, the yarn ball support force is obtained, and it is determined whether the yarn ball support force is greater than the target support force of the yarn ball. If so, the theoretical bristle density and the theoretical length of the free segment are used as design parameters to design the brush of the yarn ball support device; otherwise, the theoretical length of the free segment of the brush is re-selected. The third bristle design parameters include: the contact area of ​​a single row of bristles and the average bristle compression.

2. The yarn ball support design method as described in claim 1, characterized in that: Based on the yarn ball's maximum compression and the preset length margin of the brush's implanted section, the theoretical length of the brush's free section is selected, including: The critical value is obtained by summing the ultimate compression of the yarn bundle and the preset length margin of the implantation segment; Using the critical value as the minimum value, the range of values ​​for the theoretical length of the free segment is determined; Choose one value from the range of values ​​as the theoretical length of the free segment.

3. The yarn ball support design method as described in claim 2, characterized in that: Within the range of values, when assigning a value to the theoretical length of the free segment, the value is selected according to the rule of ascending from small to large.

4. The yarn ball support design method as described in claim 1, characterized in that: Before determining the theoretical bristle density based on the bristle theoretical stiffness, the target value of yarn friction, and the second bristle design parameters, the following steps are also included: Obtain the mapping relationship between the upper limit diameter of the yarn spool and the yarn release friction to confirm the upper limit value of the yarn friction; Based on the upper limit of yarn friction, the target value of yarn friction is determined.

5. The yarn ball support design method as described in claim 1, characterized in that: Also includes: Adjust the distance between the yarn take-up points based on the upper limit diameter of the yarn bundle to ensure that the yarn release meets the yarn take-up design requirements.

6. A yarn ball support structure, characterized in that: The yarn ball support structure (3) is made using any one of the above claims 1-5 and is used to be installed on a yarn tying machine (1). It includes a brush, which includes a brush handle (4) and brush bristles (5). Multiple brush handles (4) are provided and distributed around the yarn bobbin shaft (2). The brush bristles (5) are connected to the brush handle (4) and part of the brush bristles (5) are inserted into the brush handle (4), while the remaining part extends toward the yarn bobbin shaft (2) for contacting the yarn ball.

7. A yarn-tying machine, characterized in that: include: The yarn bobbin (2) is provided in multiple sets, and each set of the yarn bobbin (2) has two; And the yarn ball support structure according to claim 6, wherein the yarn ball support structure (3) is arranged around the circumference of the yarn bobbin axis (2).

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