Modular yarn production method
The modularly designed cooling tank, wheel pressure dewatering chamber, and pre-cleaning chamber solve the problems of loss and connection between processes in yarn production, achieving efficient cleaning and stable yarn processing, adapting to the production needs of different yarn types, and completing piercing during the cooling process, thereby improving production efficiency and quality.
Patent Information
- Authority / Receiving Office
- CN · China
- Patent Type
- Applications(China)
- Current Assignee / Owner
- Filing Date
- 2025-12-31
- Publication Date
- 2026-04-03
AI Technical Summary
Existing yarn production equipment suffers from high losses, poor connections, and incomplete removal of cotton fibers during inter-process transfers, making it difficult to adapt to diverse production needs. Furthermore, the puncturing operation is inconvenient after the yarn has cooled and hardened.
The modular design of the cooling tank, wheel pressure dewatering chamber, and pre-cleaning chamber extends the soaking path through reversing wheels, improves efficiency through multi-wheel dewatering design, and uses an ultrasonic scraper to remove cotton lint. The perforating roller in the cooling tank completes perforation before the yarn is completely hardened.
It achieves efficient connection between different processes of yarn production, reduces losses, improves drying efficiency, ensures yarn quality, reduces energy waste, and the punching operation is labor-saving and consistent in quality.
Smart Images
Figure CN121781328A_ABST
Abstract
Description
Technical Field
[0001] This invention relates to the field of textile machinery technology, and in particular to a modular yarn production method. Background Technology
[0002] Some yarns are produced using a drawing process, requiring cooling water in a cooling tank. To improve yarn functionality and surface roughness, perforations are made on the yarn surface, and corresponding functional materials (such as cooling agents and deodorizers) are stored within these perforations. Current perforation is done after the yarn has fully hardened, which is inconvenient and makes it difficult to control the consistency of the perforations. Finally, the yarn needs surface cleaning before drying to remove foreign matter adhering during production. In traditional production processes, the transfer of yarn between these different processes presents numerous problems. For example, poor coordination between processes leads to low production efficiency, affects the overall production rhythm, and causes unnecessary surface damage. Furthermore, if lint adhering to the yarn surface is not effectively removed before the drying process, this lint accumulates during drying, affecting drying efficiency and causing significant energy waste. Current technology lacks an equipment solution that can modularly integrate the pretreatment process and effectively solve the above problems. Especially when processing different types of yarn, existing equipment struggles to flexibly adjust the combination of processes, failing to meet diverse production needs. In addition, existing pretreatment equipment is significantly inadequate in terms of dewatering efficiency and cleaning effect, and cannot provide an ideal yarn condition for subsequent drying processes. Summary of the Invention
[0003] Based on the above-mentioned shortcomings of the prior art, the first objective of this invention is to provide a modular yarn production method that reduces yarn damage, ensures smooth connection between processes, and reduces the amount of cotton lint in the drying process.
[0004] The second objective of this invention is to provide a modular yarn production method that completes the punching before the yarn is fully cooled and hardened, thus solving the problem of the laborious and inconvenient process of punching the yarn after it has fully hardened.
[0005] To achieve the above objectives, the present invention adopts the following technical solution: A modular yarn production method is characterized by being completed using modular production equipment, which includes a cooling tank, a wheel-pressure dewatering chamber, and a pre-cleaning chamber. The yarn sequentially passes through the cooling tank, the wheel-pressure dewatering chamber, and the pre-cleaning chamber. The cooling tank includes a tank body containing coolant, an immersion inlet, and an immersion outlet. A reversing wheel is located below the coolant surface in the tank body. The wheel-pressure dewatering chamber includes a dewatering chamber body and several dewatering wheels rotatably mounted on the dewatering chamber body. The height of the dewatering wheels corresponds to the height of the immersion outlet. A return water pump is connected to the bottom of the dewatering chamber body and is connected to a pipe in the cooling tank. The pre-cleaning chamber includes a pre-cleaning chamber body and an ultrasonic scraper mounted inside the pre-cleaning chamber body. The pre-cleaning chamber has a yarn inlet and a yarn outlet, with the height of the yarn inlet corresponding to the height of the immersion outlet. During use, the yarn is cooled in the cooling tank, enters the wheel-pressure dewatering chamber for dewatering, and finally passes through the pre-cleaning chamber for cleaning.
[0006] This equipment integrates soaking, dewatering, and pre-cleaning processes through modular design, solving the problem of yarn loss during transfer between different processes. The cooling tank extends the yarn soaking path via reversing wheels, ensuring thorough immersion. The wheel-pressure dewatering chamber employs a multi-wheel design to improve dewatering efficiency and utilizes a return water pump for coolant recycling. The pre-cleaning chamber uses ultrasonic scrapers to effectively remove lint from the yarn surface, preparing it for subsequent drying processes. Compared to existing technologies, this equipment reduces yarn transfer between processes, lowers losses, and improves drying efficiency through pre-lint removal. The highly aligned design of each module ensures smooth yarn transport, and the return water system enables resource recycling.
[0007] Furthermore, the cooling tank, the wheel-pressure dewatering chamber, and the pre-cleaning chamber are all modular structures that can be combined according to the different adaptability of the yarn. The cooling tank, the wheel-pressure dewatering chamber, and the pre-cleaning chamber are each a separate modular structure. For example, when processing heavy fabrics, the number of wheel-pressure dewatering chamber modules can be increased, while when processing light and thin fabrics, the number of wheel-pressure dewatering chambers, i.e., the number of dewatering wheel sets, can be reduced, thus achieving flexible configuration of the production line.
[0008] Furthermore, the dewatering wheel includes a first dewatering wheel located below the yarn and a second dewatering wheel located above the yarn. The dewatering chamber has a connecting hole that rotatably connects to the end of the first dewatering wheel. The first dewatering wheel and the connecting hole are rotatably connected by a bearing. The dewatering chamber has a guide groove that mates with the end of the second dewatering wheel. The guide groove is inclined upwards towards the connecting hole. When the second dewatering wheel reaches the upper end of the guide groove, the outer circumference of the second dewatering wheel abuts against the outer circumference of the first dewatering wheel, and at this time, the lower end of the second dewatering wheel is not higher than the upper end. As the yarn passes over the upper side of the first dewatering wheel and the lower side of the second dewatering wheel, the yarn exerts a traction force on the second dewatering wheel, causing it to move along the guide groove. When the second dewatering wheel moves to the upper end of the guide groove, the two wheels form a squeezing fit. At this time, the lower end of the second dewatering wheel does not exceed the upper end of the first dewatering wheel, preventing the yarn from bending in the opposite direction during the dewatering process.
[0009] Furthermore, the soaking inlet is equipped with a first reversing wheel set, and the soaking outlet is equipped with a second reversing wheel set. The height of the dewatering wheel corresponds to the height of the second reversing wheel set. This achieves linear guidance between the dewatering wheel and the second reversing wheel set, ensuring the smoothness of the yarn passage.
[0010] Furthermore, a third reversing wheel assembly is provided at the yarn inlet, and a fourth reversing wheel assembly is provided at the yarn outlet. The height of the third reversing wheel assembly corresponds to the height of the second reversing wheel assembly. This enables reliable connection of yarn between different functional modules.
[0011] Furthermore, after passing through the third reversing wheel set, the yarn enters the pre-cleaning chamber and then exits the pre-cleaning chamber after passing through the fourth reversing wheel set. The ultrasonic scraper is located on the upper side of the yarn. The ultrasonic scraper generates mechanical vibration through a piezoelectric ceramic transducer, and the vibration is transmitted to the working surface of the scraper, thereby achieving the removal of cotton fibers from the yarn surface.
[0012] Furthermore, in the direction perpendicular to the yarn movement, the width of the pre-cleaning chamber is greater than the diameter of the yarn, and the bottom of the pre-cleaning chamber is provided with an inclined guide surface, with a discharge port at the lowest point of the guide surface. This allows the cotton fibers stripped off by the ultrasonic scraper to fall under the yarn and then be guided by the guide surface to converge at the discharge port.
[0013] Furthermore, the ultrasonic scraper has two sets along the yarn movement direction, and the two sets of ultrasonic scraper plates are set at an angle. The two sets of ultrasonic scraper plates work together to provide a reliable scraping action.
[0014] Furthermore, a filter device is installed above the inlet of the pipe connected to the return water pump inside the dehydration chamber. This ensures the reliability of the return water pump, and the return water pump allows the fabric softener to be repeatedly recycled, improving the overall environmental performance of the equipment.
[0015] Preferably, the first reversing wheel on the feed side of the trough is a roller structure, and is called a perforating roller. The perforating roller has an annular limiting groove on its circumferential surface, which extends circumferentially. The perforating roller is a non-ferromagnetic structure. The perforating roller has a cylindrical inner cavity coaxial with the perforating roller. The inner cavity has a pressing post with a magnetic structure. The bottom wall of the annular limiting groove of the perforating roller has a plurality of pin holes evenly distributed circumferentially along the annular limiting groove of the perforating roller. The pin holes penetrate into the inner cavity and extend radially along the perforating roller. A perforating needle with its tip facing outward is inserted into the pin hole. The perforating needle is a ferromagnetic structure. In use, the yarn passes through the annular limiting groove of the perforating roller and is located on the lower side of the perforating roller. During use, the pressing column pushes the needle, located below, outwards to pierce the yarn surface. As the needle moves upwards, the pressing column's suction effect causes it to retract into the piercing roller, thus improving safety. This method allows the needle to gradually rise during piercing, avoiding the bending that can occur with a constantly exposed needle. The piercing roller is located at the front, while the yarn is still warm and not fully hardened, making piercing easier and less strenuous. The roller design, instead of a wheel, increases the weight of the pressing column, thereby driving the needle to pierce the yarn.
[0016] Preferably, the device also includes a piercing roller extrusion roller located below the piercing roller. The piercing roller extrusion roller has an annular structure extending into the annular limiting groove of the piercing roller section. The annular annular antrusion roller extends circumferentially along the piercing roller extrusion roller. This improves the reliability of the piercing process.
[0017] Preferably, the cooling tank has vertical grooves for the perforating rollers on two opposite walls. A slider for the perforating rollers is slidably connected within these grooves. The slider is connected to the cooling tank via a lifting structure. The two ends of the perforating roller's compression roller are rotatably connected to the two sliders. In use, the height of the compression roller is adjusted using the lifting structure, changing the depth of the perforating roller's anvil inserted into the annular guide groove, thereby altering the depth of the perforations on the yarn.
[0018] Preferably, the lifting structure of the perforating roller includes an upper threaded hole on the lower surface of the perforating roller slider, a lower threaded hole on the bottom wall of the cooling tank, and a double-ended screw. One end of the double-ended screw is threaded into the upper threaded hole, and the other end is threaded into the lower threaded hole. The threads at both ends of the double-ended screw are in opposite directions. In use, the depth to which the perforating roller anvil is inserted into the annular guide groove of the perforating roller is changed by rotating the double-ended screw. Adjustment is convenient.
[0019] Preferably, the device also includes a feed tube sleeved on the yarn, located on the feed side of the punching roller. An arc-shaped baffle is connected to the lower end of the feed tube. The baffle is coaxial with the punching roller and passes through an annular limiting groove in the punching roller section. The free end of the baffle is located at the joint between the extrusion roller and the punching roller in the punching roller section. This allows the yarn to easily enter between the anvil and the punching roller in the punching roller section.
[0020] Preferably, the device also includes a guide wheel compression wheel located below the guide wheel. The piercing wheel has an annular limiting groove on its circumferential surface, extending circumferentially along the guide wheel. The guide wheel compression wheel has an annular anvil that extends into the annular limiting groove, and the annular anvil extends circumferentially along the guide wheel compression wheel. This allows for yarn drawing.
[0021] Preferably, the cooling tank has vertical guide wheel grooves on two opposite walls, and guide wheel sliders are slidably connected within these grooves. The guide wheel sliders are connected to the cooling tank via a guide wheel lifting structure, and the two ends of the guide wheel extrusion rollers are rotatably connected to the two guide wheel sliders in a one-to-one correspondence. This allows for adjustment of the clamping force on the yarn.
[0022] Preferably, the guide wheel lifting structure includes an upper threaded hole on the lower surface of the guide wheel slider, a lower threaded hole on the bottom wall of the cooling tank, and a double-ended screw. One end of the double-ended screw is threaded into the upper threaded hole, and the other end is threaded into the lower threaded hole. The threads at both ends of the double-ended screw are in opposite directions. In use, the pressing force on the yarn is adjusted by rotating the double-ended screw, making adjustment convenient.
[0023] Preferably, when the second dewatering wheel moves along the guide groove to the same height as the axis of the first dewatering wheel, the distance between the second and first dewatering wheels is less than the sum of the radii of the second and first dewatering wheels. This allows the wear of the dewatering wheels to be compensated for by adjusting the height of the second dewatering wheel, ensuring reliable squeezing and dewatering of the yarn.
[0024] Preferably, the dehydration chamber is equipped with two sets of suspension seats. Each set of suspension seats includes two suspension seats, and the guide groove is disposed on the suspension seat. Both ends of a second dehydration wheel pass through the guide grooves on the two suspension seats in the same set. The upper end of the suspension seat is rotatably connected to the wall of the dehydration chamber via a suspension shaft head, and the lower section is equipped with a drive shaft head parallel to the suspension shaft head. The drive shaft heads on the suspension seats located on the same side of the dehydration chamber in both sets of suspension seats are connected together by a connecting rod. The connecting rod is connected to a connecting rod drive structure that can stop at the current position. This allows for easy adjustment of the guide groove angle, thus achieving adjustment of the extrusion pressure.
[0025] Preferably, when the suspension seat is in its natural drooping state, the tilt angle of the guide groove is the minimum value of a set tilt angle range. The linkage drive structure includes a push plate abutting against one end of the linkage, a push rod with a drive hole connected to the side of the push plate away from the linkage, and a horizontal threaded rod passing through the drive hole. The horizontal threaded rod is threadedly connected to the side wall of the dehydration chamber and passes through the side wall of the dehydration chamber. When the push plate pushes the linkage, it drives the tilt angle of the guide groove to increase. In use, the suspension seat can be adjusted to a set angle by rotating the horizontal threaded rod. Adjustment is convenient and it can automatically maintain the current angle.
[0026] Preferably, the top plate is provided with a vertical connecting groove, and the connecting rod abuts against the vertical connecting groove. This allows the lifting direction generated during the translation of the connecting rod to be controlled, reducing the torque generated on the suspension shaft.
[0027] Preferably, the wall of the dehydration chamber is provided with an arc-shaped limiting groove coaxial with the suspension shaft head on the same suspension seat, and the connecting rod is provided with a swing limiting block slidably connected in the arc-shaped limiting groove. This can improve the stability of the suspension seat when swinging.
[0028] Preferably, a protractor is provided on the wall of the dehydration chamber. The center of the protractor is located on the axis of the suspension shaft on a suspension seat. The axis of the suspension shaft is coaxial with the circle of the protractor. The suspension seat is provided with a pointer indicating the scale value on the protractor. The width of the protractor aligned with the pointer is the inclination angle of the guide groove. This allows for convenient and intuitive determination of the angle of the guide groove.
[0029] As can be seen from the above, the modular yarn pretreatment equipment provided in this application achieves efficient connection and automated processing of the yarn pretreatment process through the coordinated work of the modularly designed cooling tank, wheel pressure dewatering chamber and pre-cleaning chamber. It effectively solves the technical problems existing in traditional processes, such as mechanical wear, poor process connection and incomplete removal of cotton fibers. It has the advantages of improving production efficiency, ensuring yarn quality and saving energy. It also completes the piercing of the yarn while cooling it, with a compact structure and convenient piercing. Attached Figure Description
[0030] Figure 1 This is a structural schematic diagram of Embodiment 1 of the modular production equipment; Figure 2 This is a schematic diagram of the structure of the wheel pressure dehydration chamber; Figure 3 This is a schematic diagram of the structure of the wheel pressure dewatering chamber during wheel pressure dewatering; Figure 4 This is a top view of the internal structure of the pre-cleaning chamber in this invention; Figure 5 This is a schematic diagram of the cooling tank in Embodiment 2; Figure 6 for Figure 5 A magnified view of a portion of point A; Figure 7 for Figure 5 A magnified view of a portion of point B; Figure 8 This is a schematic diagram of the wheel pressure dehydration chamber in Example 2.
[0031] In the diagram: 1. Yarn; 2. Cooling tank; 3. Coolant; 4. Reversing wheel; 5. Dewatering chamber; 6. First dewatering wheel; 7. Second dewatering wheel; 8. Guide groove; 9. Return water pump; 10. Filter device; 11. Pre-cleaning chamber; 12. Guide surface; 120. Discharge port; 121. Ultrasonic scraper; 13. First reversing wheel group; 14. Second reversing wheel group; 15. Third reversing wheel group; 16. Fourth reversing wheel group; 17. Perforating roller; 20. Annular limiting groove of perforating roller section; 21. Inner cavity; 22. Pressing column; 23. Perforating needle; 24. Extrusion roller of perforating roller section; 25. Anvil of perforating roller section; 26. Vertical sliding groove of perforating roller section; 27. Slider of perforating roller section; 28. 30. Double-ended screw of the perforating roller section; 31. Feed pipe; 32. Baffle plate; 33. Free end of the baffle plate; 34. Extrusion roller of the reversing wheel section; 35. Annular limiting groove of the reversing wheel section; 36. Anvil plate of the reversing wheel section; 37. Vertical sliding groove of the reversing wheel section; 38. Slider of the reversing wheel section; 39. Double-ended screw of the reversing wheel section; 40. Dewatering wheel pair; 41. Suspension seat; 42. Suspension shaft head; 43. Drive shaft head; 44. Connecting rod; 45. Push plate; 46. Push rod; 47. Horizontal threaded rod; 48. Vertical connecting groove; 49. Arc-shaped limiting groove; 50. Swing limiting block; 51. Protractor; 52. Suspension seat coaxial with the circular protractor and the axis of the suspension shaft head; 53. Pointer. Detailed Implementation
[0032] To make the objectives, technical solutions, and advantages of this invention clearer, the technical solutions of the embodiments of this invention will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some, not all, of the embodiments of this invention. Based on the embodiments of this invention, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of this invention.
[0033] Example 1, see Figures 1 to 4 A modular yarn production method is disclosed, which is accomplished using modular production equipment. The modular production equipment includes a cooling tank 2, a wheel-pressure dewatering chamber, and a pre-cleaning chamber. Yarn 1 passes through the cooling tank 2, the wheel-pressure dewatering chamber, and the pre-cleaning chamber sequentially. The cooling tank 2 includes a tank body containing coolant 3. The tank body has an immersion inlet and an immersion outlet. A reversing wheel 4 is located below the surface of the coolant 3 in the tank body. The wheel-pressure dewatering chamber includes a dewatering chamber body 5 and several dewatering wheels 6 rotatably mounted on the dewatering chamber body 5. The height of the dewatering wheels 6 corresponds to the height of the immersion outlet. A return water pump 10 is connected to the bottom of the dewatering chamber body 5 and is connected to a pipe in the cooling tank 2. The pre-cleaning chamber includes a pre-cleaning chamber body 12 and an ultrasonic scraper 13 mounted within the pre-cleaning chamber. The pre-cleaning chamber has a yarn inlet and a yarn outlet, the height of which corresponds to the height of the immersion outlet.
[0034] The cooling tank 2 can be made of stainless steel or corrosion-resistant plastic. The coolant 3 can be a weakly alkaline or neutral solution depending on the yarn material. The number of reversing wheels 4 can be multiple, for example, 3-5, depending on the tank length, to extend the yarn soaking path. The soaking inlet and outlet can be sealed to prevent coolant 3 from overflowing. The surface of the dewatering wheels 6 in the wheel pressure dewatering chamber can be covered with a rubber or silicone layer to increase friction and protect the yarn. The dewatering wheels 6 can be arranged in a staggered pattern, with 4-6 wheels depending on the dewatering requirements. The return water pump 10 can be equipped with a flow control valve to adjust the return water speed. The ultrasonic scraper 13 in the pre-cleaning chamber has an adjustable frequency, with a recommended range of 20-40kHz. The distance between the scraper and the yarn can be set to 5-10mm. Brush seals can be installed at the yarn inlet and outlet to prevent lint from escaping.
[0035] The modular design integrates the soaking, dewatering, and pre-cleaning processes, solving the problem of yarn loss during transfer between different processes. The cooling tank 2 extends the yarn soaking path via a reversing wheel 4, ensuring thorough immersion. The wheel-pressure dewatering chamber employs a multi-wheel design to improve dewatering efficiency and utilizes a return water pump 10 to recycle the coolant 3. The pre-cleaning chamber uses an ultrasonic scraper 13 to effectively remove lint from the yarn surface, preparing it for subsequent drying processes. Compared to existing technologies, this equipment reduces yarn transfer between processes, lowers losses, and improves drying efficiency through pre-cleaning. The highly symmetrical design of each module ensures smooth yarn transport, and the return water system enables resource recycling.
[0036] Furthermore, the cooling tank 2, the wheel-pressure dewatering chamber, and the pre-cleaning chamber are all modular structures that can be combined according to the different adaptability requirements of yarn 1. The cooling tank 2, wheel-pressure dewatering chamber, and pre-cleaning chamber are individual modules that can be used in multiple combinations as needed. The cooling tank 2, wheel-pressure dewatering chamber, and pre-cleaning chamber can be quickly connected via snap-fit or bolts. Pneumatic quick-connect fittings are used to connect the modules. For example, when processing heavy fabrics, the number of wheel-pressure dewatering chamber modules can be increased; when processing light fabrics, the number of wheel-pressure dewatering chambers (i.e., the number of dewatering wheels) can be reduced to 6 sets, achieving flexible configuration of the production line.
[0037] This application addresses the challenge of adapting traditional fixed production lines to the production of various yarn types by breaking down the pretreatment process into independently detachable physical modules. Since each module possesses independent functional integrity, changing yarn types only requires adjusting the corresponding module parameters or replacing specific units, without the need for overall equipment modification. For example, a low-frequency ultrasonic scraping module can be used for high-count yarn fabrics, while six sets of high-pressure dewatering wheels are suitable for woolen fabrics. This modular design significantly reduces downtime during process changeovers and minimizes the risk of yarn damage due to equipment incompatibility.
[0038] Furthermore, the dewatering wheel 6 includes a first dewatering wheel 7 located on the lower side of the yarn 1 and a second dewatering wheel 8 located on the upper side of the yarn 1. The dewatering chamber 5 is provided with a connecting hole that rotatably connects to the end of the first dewatering wheel 7. The first dewatering wheel 7 and the connecting hole are rotatably connected by a bearing. The dewatering chamber 5 is provided with a guide groove 9 that rotatably connects to the end of the second dewatering wheel 8. The guide groove 9 is inclined upward towards the connecting hole. When the second dewatering wheel 8 reaches the upper end of the guide groove 9, the outer periphery of the second dewatering wheel 8 abuts against the outer periphery of the first dewatering wheel 7, and at this time, the lower end of the second dewatering wheel 8 is not higher than the upper end of the first dewatering wheel 7.
[0039] Specifically, the first dewatering wheel 7 serves as a fixed support wheel, achieving a stable rotational connection with the dewatering chamber 5 via bearings. The second dewatering wheel 8 adopts an adjustable design, with its end moving along the inclined guide groove 9, thereby adjusting the gap with the first dewatering wheel 7. The yarn passes over the upper side of the first dewatering wheel 7 and the lower side of the second dewatering wheel 8. In a preferred embodiment, the inclination angle of the guide groove 9 is 15-30 degrees, ensuring that the second dewatering wheel 8 can naturally press down on the yarn under gravity. During the process of the yarn 1 being passed through, it generates a traction force on the second dewatering wheel 8, causing the second dewatering wheel 8 to move along the guide groove 9. When the second dewatering wheel 8 moves to the upper end of the guide groove 9, the two wheels form a squeezing fit. At this time, the lower end of the second dewatering wheel 8 does not exceed the upper end of the first dewatering wheel 7, preventing the yarn from bending in the opposite direction during the dewatering process.
[0040] This application achieves efficient yarn dewatering through a dual-wheel structure. The first dewatering wheel 7 provides a stable support surface, while the second dewatering wheel 8, with its adjustable design, accommodates yarns of varying thicknesses. An inclined guide groove 9 ensures uniform pressure application. Compared to traditional single-wheel dewatering methods, this design significantly improves dewatering efficiency while avoiding yarn damage caused by uneven pressure. In practical implementation, the pressure between the two wheels can be precisely controlled by adjusting the angle of the guide groove 9, thereby achieving optimal dewatering results.
[0041] Furthermore, the soaking inlet is provided with a first reversing wheel group 14, the soaking outlet is provided with a second reversing wheel group 15, and the height of the dewatering wheel 6 corresponds to the height of the second reversing wheel group 15.
[0042] The first reversing wheel assembly 14 and the second reversing wheel assembly 15 are each composed of multiple parallel reversing wheels. The surfaces of the reversing wheels may be provided with anti-slip textures or covered with a rubber layer to increase friction with the yarn. The diameter of the reversing wheels is preferably in the range of 50-150 mm, and the wheel spacing is adjusted to 10-30 mm according to the yarn thickness. As a preferred embodiment, at least one reversing wheel in the second reversing wheel assembly 15 may be configured as a power drive wheel to assist in yarn transmission.
[0043] This application achieves a smooth transition of yarn during inter-process transfer by setting up a highly matched reversing wheel set and a dewatering wheel 6. Specifically, the first reversing wheel set 14 ensures that the yarn enters the cooling tank 2 with a stable tension, and the height correspondence between the second reversing wheel set 15 and the dewatering wheel 6 prevents the yarn from sagging or being overstretched during transfer. The reversing wheel set arrangement allows the yarn to maintain a predetermined trajectory when reversing direction below the liquid surface, preventing yarn tangling or deviation. Compared with the prior art, this structure significantly reduces wrinkles and deformation during yarn transfer, while also reducing the risk of fabric breakage due to uneven tension. The adjustable design of the reversing wheel set can also adapt to the processing needs of yarns of different thicknesses, improving the versatility of the equipment.
[0044] Furthermore, the yarn inlet is provided with a third reversing wheel set 16, and the yarn outlet is provided with a fourth reversing wheel set 17. The height of the third reversing wheel set 16 corresponds to the height of the second reversing wheel set 15.
[0045] Specifically, the third reversing wheel set 16 and the fourth reversing wheel set 17 are respectively located at the yarn inlet and yarn outlet of the pre-cleaning chamber. The reversing wheel set typically consists of two parallel wheel sets spaced apart vertically, used to guide the yarn smoothly into and out of the pre-cleaning chamber. The height of the third reversing wheel set 16 is consistent with the height of the second reversing wheel set 15 at the outlet of the cooling tank 2, ensuring that the yarn remains horizontal during transfer and avoiding uneven yarn tension or deformation due to height differences. As a preferred embodiment, the reversing wheel set can be made of stainless steel with a polished surface to reduce friction; the wheel spacing can be adjusted according to the yarn width, typically set to 1.2-1.5 times the yarn width.
[0046] Therefore, by setting up a reversing wheel set with a matching height, the tension control problem caused by the inconsistency in yarn height during transfer between different processing units is solved. Specifically, when the yarn enters the pre-cleaning chamber from the cooling tank 2 via the wheel pressure dewatering chamber, the height correspondence between the third reversing wheel set 16 and the second reversing wheel set 15 ensures the horizontal continuity of the yarn transmission path. This avoids the problem of needing additional tension adjustment devices due to height differences in traditional equipment and reduces wrinkles and deformation of the yarn during transfer. Compared with existing technologies, this design significantly improves the stability of yarn transmission while simplifying the equipment structure, facilitating rapid docking when modularly assembled.
[0047] Furthermore, the yarn enters the pre-cleaning chamber after passing through the third reversing wheel group 16 and leaves the pre-cleaning chamber after passing through the fourth reversing wheel group 17, with the ultrasonic scraper 13 located on the upper side of the yarn.
[0048] Specifically, the ultrasonic scraper 13 operates using high-frequency vibration, preferably within the range of 20kHz-40kHz. The ultrasonic scraper 13 generates mechanical vibration through a piezoelectric ceramic transducer, which is transmitted to the working surface of the scraper, thereby removing lint from the yarn surface. In a preferred embodiment, the working surface of the ultrasonic scraper 13 maintains a distance of 1-3mm from the yarn surface; this distance can be adjusted using adjusting bolts. Furthermore, the working surface of the scraper can be configured with a serrated or wavy structure to enhance the lint removal effect. A negative pressure suction device can be installed in the pre-cleaning chamber to promptly remove the removed lint and prevent secondary contamination.
[0049] Therefore, this application effectively solves the problem of cotton lint accumulation during the drying process in traditional processes by using an ultrasonic scraper plate 13 for yarn pretreatment. Ultrasonic vibration can penetrate deep into the fiber gaps, efficiently removing surface cotton lint without damaging the yarn. Compared with mechanical scraping methods, this solution has the advantages of thorough cleaning and no yarn damage. The modular design of the pre-cleaning chamber allows it to flexibly adapt to yarns of different widths, and seamless connection with preceding and following processes can be achieved by adjusting the height of the reversing wheel assembly. This solution significantly improves pretreatment efficiency, creating favorable conditions for subsequent drying processes.
[0050] Furthermore, in the direction of vertical yarn movement, the width of the pre-cleaning chamber is greater than the diameter of the yarn, and the bottom of the pre-cleaning chamber is provided with an inclined guide surface 120, and the lowest point of the guide surface 120 is provided with a discharge port 121.
[0051] Specifically, the width of the pre-cleaning chamber is designed to be greater than the width of the yarn to prevent friction or jamming between the yarn and the side wall of the chamber during movement. The inclined guide surface 120 allows lint and other impurities cleaned from the yarn surface to slide naturally down the inclined surface and be discharged through the discharge port 121. The inclined angle of the guide surface 120 is preferably 15-30 degrees to ensure that impurities slide smoothly without accumulating. The discharge port 121 can be connected to an external collection device or pipeline to achieve automated impurity cleaning. As a preferred embodiment, the guide surface 120 can be made of stainless steel with a polished surface to reduce frictional resistance.
[0052] Therefore, this application effectively solves the problem of collecting and cleaning impurities such as cotton fibers during the pre-cleaning process of yarn 1 by optimizing the structural design of the pre-cleaning chamber. Compared with the prior art, the cooperative design of the inclined guide surface 120 and the discharge port 121 can realize the automatic collection and discharge of impurities, avoid the inconvenience of manual cleaning, and at the same time ensure the continuity and efficiency of the pre-treatment process.
[0053] Furthermore, the ultrasonic scraper 13 is provided with two sets along the yarn moving direction, and the two sets of ultrasonic scraper 13 are arranged at an angle.
[0054] Specifically, the ultrasonic scraper blades 13 are arranged in two sets parallel to the yarn movement direction, forming a certain angle between the two sets of scraper blades. In a preferred embodiment, the first set of scraper blades can be set at an angle of 10°-45° to the yarn movement direction, and the second set of scraper blades can be set at an angle of 90°-120° to the yarn movement direction. The two sets of scraper blades can be driven by ultrasonic generators of different frequencies; for example, the first set uses a 28kHz frequency, and the second set uses a 40kHz frequency. The installation angle of the scraper blades can be finely adjusted by an adjustment mechanism to adapt to the processing requirements of yarns of different thicknesses.
[0055] This application utilizes two sets of ultrasonic scraper blades 13 arranged at an angle to achieve multi-angle cleaning of cotton fibers on the yarn surface. The first set of scraper blades primarily removes larger particles and loose cotton fibers adhering to the yarn surface, while the second set targets finer fibers for deeper cleaning. Because the two sets of scraper blades are arranged at an angle, the ultrasonic action area overlaps, preventing the formation of cleaning dead zones. Simultaneously, the different angles subject the yarn to multi-directional vibration during movement, contributing to improved cleaning efficiency. This design is particularly suitable for processing wider yarns 1, ensuring uniform cleaning across the entire width of the yarn.
[0056] Furthermore, a filter device 11 is installed above the inlet of the pipe connected to the return water pump 10 within the dewatering chamber 5. The filter device 11 can be made of metal filter screen, multi-layer filter cloth, or sintered porous material, and its pore size is preferably in the range of 0.1-1mm. In specific implementations, the filter device 11 can be designed as a detachable drawer-type structure for easy regular cleaning and maintenance.
[0057] This solution effectively intercepts fiber impurities shed during the dehydration process by installing a filter device 11 at the inlet of the return water pipe, preventing them from re-entering the cooling tank 2 with the return water. Specifically, when the yarn 1 is squeezed by the dehydration wheel 6, fiber fragments and residual cotton fibers fall with the water to the bottom of the dehydration chamber 5. The filter device 11 blocks them above the suction inlet of the return water pump 10, allowing only clean liquid to flow back to the cooling tank 2 through the pipe. This achieves the circulation and purification of the coolant 3, reducing the problem of decreased yarn cleanliness caused by repeated contamination by impurities, and also reducing the workload of the ultrasonic scraper 13 in the subsequent pre-cleaning chamber. Compared with the existing technology of direct return, this design significantly improves the stability of the liquid circulation system and extends the service life of the coolant 3.
[0058] Example 2 differs from Example 1 in that: See Figures 5 to 7The first reversing wheel on the feed side of the trough is a roller structure, and is called the perforating roller 20. The circumferential surface of the perforating roller is provided with an annular limiting groove 21 for the perforating roller section. The annular limiting groove for the perforating roller section extends along the circumference of the perforating roller. The perforating roller is a non-ferromagnetic structure. The perforating roller is provided with a cylindrical inner cavity 22 coaxial with the perforating roller. The inner cavity is provided with a pressing column 23 with a magnetic structure. The bottom wall of the annular limiting groove for the perforating roller section is provided with a number of pin holes evenly distributed along the circumference of the annular limiting groove for the perforating roller section. The pin holes penetrate into the inner cavity and extend along the radial direction of the perforating roller. A perforating needle 24 with the needle tip facing outward is inserted into the pin hole. The perforating needle is a ferromagnetic structure. When in use, the yarn 1 passes through the annular limiting groove for the perforating roller section and is located on the lower side of the perforating roller. In use, the pressing column pushes the needle below out to pierce the yarn surface. When the needle moves upward, the pressing column's suction effect causes the needle to retract into the piercing roller, thus improving safety. This method allows the needle to gradually rise during piercing, avoiding the bending that can occur when the needle is always exposed. It also includes a piercing roller compression roller 25 located below the piercing roller. The piercing roller compression roller has an annular structure piercing roller anvil 26 that extends into the annular limiting groove of the piercing roller. The annular anvil extends circumferentially along the piercing roller compression roller. Vertical grooves 27 for the piercing roller are provided on two opposite walls of the cooling tank. A piercing roller slider 28 is slidably connected within these grooves. The piercing roller slider is connected to the cooling tank via a piercing roller lifting structure. The two ends of the piercing roller compression roller are rotatably connected to the two piercing roller sliders. The lifting structure of the perforating roller includes an upper threaded hole on the lower surface of the perforating roller slider, a lower threaded hole on the bottom wall of the cooling tank, and a double-ended screw 30. One end of the double-ended screw is threaded into the upper threaded hole, and the other end is threaded into the lower threaded hole. The threads at both ends of the double-ended screw are in opposite directions. In use, the depth of the perforating roller anvil inserted into the annular guide groove of the perforating roller is changed by rotating the double-ended screw. It also includes a feed pipe 31 sleeved on the yarn, located on the feed side of the perforating roller. An arc-shaped baffle 32 is connected to the lower end of the feed pipe. The baffle is coaxial with the perforating roller and passes through the annular limiting groove of the perforating roller. The free end 33 of the baffle is located at the joint between the perforating roller and the extrusion roller. It also includes a reversing wheel compression wheel 34 located below the reversing wheel 4. The circumferential surface of the pierced wheel is provided with a reversing wheel annular limiting groove 35, which extends along the circumference of the reversing wheel. The reversing wheel compression wheel is provided with a reversing wheel anvil 36 with an annular structure that extends into the reversing wheel annular limiting groove. The pierced wheel annular anvil extends along the circumference of the reversing wheel compression wheel.The cooling tank has two opposing vertical sliding grooves 37 for the reversing wheel section. A reversing wheel slider 38 is slidably connected within the vertical sliding groove. The reversing wheel slider is connected to the cooling tank via a reversing wheel lifting structure. The two ends of the reversing wheel extrusion wheel are rotatably connected to the two reversing wheel sliders in a corresponding manner. The reversing wheel lifting structure includes an upper threaded hole on the lower surface of the reversing wheel slider, a lower threaded hole on the bottom wall of the cooling tank, and a double-ended screw 39. One end of the double-ended screw is threaded into the upper threaded hole, and the other end is threaded into the lower threaded hole. The threads at both ends of the double-ended screw have opposite directions.
[0059] See Figure 8The dewatering wheel includes several dewatering wheel pairs 40, distributed along the yarn's travel direction. Each dewatering wheel pair includes a first dewatering wheel 7 located on the underside of the yarn and a second dewatering wheel 8 located on the upper side of the yarn. The dewatering chamber has a connecting hole that rotatably connects to the end of the first dewatering wheel. The first dewatering wheel and the connecting hole are rotatably connected by a bearing. The dewatering chamber has a guide groove 9 that mates with the end of the second dewatering wheel. The guide groove is inclined upwards towards the connecting hole. When the second dewatering wheel reaches the upper end of the guide groove, the outer circumference of the second dewatering wheel abuts against the outer circumference of the first dewatering wheel, and at this time, the lower end of the second dewatering wheel is not higher than the upper end of the first dewatering wheel. When the second dewatering wheel moves along the guide groove to the same height as the axis of the first dewatering wheel, the radius of the second dewatering wheel is less than the sum of the radius of the second dewatering wheel and the radius of the first dewatering wheel. The dehydration chamber is equipped with two sets of suspension seats. Each set of suspension seats includes two suspension seats 41, with guide grooves provided in the suspension seats. The two ends of a second dehydration wheel pass through the guide grooves on the two suspension seats in the same set of suspension seats. The upper end of the suspension seat is rotatably connected to the wall of the dehydration chamber 5 via a suspension shaft head 42, and the lower section is provided with a drive shaft head 43 parallel to the suspension shaft head. The drive shaft heads on the suspension seats on the same side of the dehydration chamber are connected together by a connecting rod 44. The connecting rod is connected to a connecting rod drive structure that can stop at the current position. When the suspension seat is in a natural hanging state, the tilt angle of the guide groove is the minimum value of the set tilt angle range. The connecting rod drive structure includes a push plate 45 abutting against one end of the connecting rod, a push rod 46 with a drive hole connected to the side of the push plate away from the connecting rod, and a horizontal threaded rod 47 passing through the drive hole. The horizontal threaded rod is threadedly connected to the side wall of the dehydration chamber and the tube passes through the side wall of the water chamber. When the push plate pushes the connecting rod, the tilt angle of the drive guide groove increases. The top plate has a vertical connecting groove 48, and the connecting rod abuts in the vertical connecting groove. The wall of the dehydration chamber has an arc-shaped limiting groove 49 coaxial with the suspension shaft head on the same suspension seat, and the connecting rod has a swing limiting block 50 slidably connected in the arc-shaped limiting groove. The wall of the dehydration chamber has a protractor 51, the center of which is located on the axis of the suspension shaft head on a suspension seat. The suspension seat 52, coaxial with the axis of the suspension shaft head and the circle of the protractor, has a pointer 53 indicating the scale value on the protractor. The width of the protractor aligned with the pointer is the inclination angle of the guide groove.
Claims
1. A modular yarn production method, characterized in that, This process is accomplished using modular production equipment, which includes a cooling tank, a wheel-pressure dewatering chamber, and a pre-cleaning chamber. The yarn passes through these three chambers sequentially. The cooling tank consists of a tank body containing coolant, an immersion inlet, and an immersion outlet. A reversing wheel is located below the coolant level in the tank body. The wheel-pressure dewatering chamber includes a dewatering chamber body and several dewatering wheels rotatably mounted on it. The height of the dewatering wheels corresponds to the height of the immersion outlet. A return water pump is connected to the bottom of the dewatering chamber body and is connected to the cooling tank pipeline. The pre-cleaning chamber includes a pre-cleaning chamber body and an ultrasonic scraper mounted within it. The pre-cleaning chamber has a yarn inlet and a yarn outlet, with the height of the yarn inlet corresponding to the height of the immersion outlet. During use, the yarn is cooled in the cooling tank, enters the wheel-pressure dewatering chamber for dewatering, and finally passes through the pre-cleaning chamber for cleaning.
2. The modular yarn production method according to claim 1, characterized in that, The cooling tank, wheel pressure dehydration chamber, and pre-cleaning chamber are all modular structures that can be combined according to the different adaptability of the yarn.
3. The modular yarn production method according to claim 1, characterized in that, The dewatering wheel includes a first dewatering wheel located on the lower side of the yarn and a second dewatering wheel located on the upper side of the yarn. The dewatering chamber body is provided with a connecting hole that is rotatably connected to the end of the first dewatering wheel. The first dewatering wheel and the connecting hole are rotatably connected by a bearing. The dewatering chamber body is provided with a guide groove that is rotatably connected to the end of the second dewatering wheel. The guide groove is inclined upward towards the connecting hole. When the second dewatering wheel reaches the upper end of the guide groove, the outer circumference of the second dewatering wheel abuts against the outer circumference of the first dewatering wheel, and at this time, the lower end of the second dewatering wheel is not higher than the upper end of the second dewatering wheel.
4. The modular yarn production method according to claim 1, characterized in that, The soaking inlet is equipped with a first guide wheel assembly, and the soaking outlet is equipped with a second guide wheel assembly. The height of the dehydration wheel corresponds to the height of the second guide wheel assembly.
5. The modular yarn production method according to claim 1, characterized in that, The yarn inlet is provided with a third guide wheel group, and the yarn outlet is provided with a fourth guide wheel group. The height of the third guide wheel group corresponds to the height of the second guide wheel group.
6. A modular yarn production method according to claim 6, characterized in that, The ultrasonic scraper plate has two sets along the yarn movement direction, and the two sets of ultrasonic scraper plates are set at an angle.
7. A modular yarn production method according to claim 1, characterized in that, The first reversing wheel located on the feed side of the trough is a roller structure, referred to as the perforating roller. The perforating roller has an annular limiting groove on its circumferential surface, extending circumferentially. The perforating roller is a non-ferromagnetic structure, and has a cylindrical inner cavity coaxial with it. A magnetic pressing post is located within the inner cavity. The bottom wall of the annular limiting groove has a ring-shaped groove extending circumferentially along the perforating roller. A plurality of pinholes are evenly distributed around the circumference of the limiting groove. The pinholes penetrate into the inner cavity and extend radially along the piercing roller. A piercing needle with its tip facing outward is inserted into the pinhole. The piercing needle has a ferromagnetic structure. When in use, the yarn passes through the annular limiting groove of the piercing roller and is located on the lower side of the piercing roller. When in use, under the action of the pressing column, the needle located below is pressed out and pierces the surface of the yarn. When the needle moves to the upward direction, the adsorption effect of the pressing column on the needle causes the needle to retract into the piercing roller.
8. A modular yarn production method according to claim 7, characterized in that, It also includes a piercing roller extrusion roller located below the piercing roller. The piercing roller extrusion roller is provided with an annular structure piercing roller anvil that extends into the annular limiting groove of the piercing roller. The annular anvil of the piercing roller extends circumferentially along the piercing roller extrusion roller. Vertical sliding grooves of the piercing roller are provided on two opposite walls of the cooling tank. A piercing roller slider is slidably connected in the vertical sliding groove of the piercing roller. The piercing roller slider is connected to the cooling tank through a piercing roller lifting structure. The two ends of the piercing roller extrusion roller are rotatably connected to the two piercing roller sliders one-to-one.
9. A modular yarn production method according to claim 8, characterized in that, It also includes a feed pipe sleeved on the yarn, located on the feed side of the punching roller. An arc-shaped baffle is connected to the lower end of the feed pipe. The baffle is coaxial with the punching roller and passes through an annular limiting groove in the punching roller section. The free end of the baffle is located at the joint between the extrusion roller and the punching roller in the punching roller section. This allows the yarn to easily enter between the anvil and the punching roller in the punching roller section.
10. The modular yarn production method according to claim 3, characterized in that, The dehydration chamber is equipped with two sets of suspension seats. Each set of suspension seats includes two suspension seats. The guide groove is provided in the suspension seat. The two ends of a second dehydration wheel pass through the guide grooves on the two suspension seats in the same set of suspension seats. The upper end of the suspension seat is rotatably connected to the wall of the dehydration chamber through a suspension shaft head. The lower section is provided with a drive shaft head parallel to the suspension shaft head. The drive shaft heads on the suspension seats on the same side of the dehydration chamber of the two sets of suspension seats are connected together by a connecting rod. The connecting rod is connected to a connecting rod drive structure that can stop at the current position.