A yarn leveling guide roller for a high speed warping machine

Abstract

The utility model discloses a kind of yarn uniformity guide roller for high-speed warping machine, which is suitable for the stable support and axial uniform distribution of warp yarn in high-speed warping process. The guide roller includes a cylindrical hollow roller body, a shaft and a bearing seat mounting structure connected coaxially, the shaft is connected to a drive motor at one end, and the roller body surface is provided with a plurality of evenly distributed spiral strip-shaped protrusions along the axial direction. The top end of the spiral strip-shaped protrusion is a circular arc surface (radius 0.3-0.8 mm, height 0.2-0.5 mm), the spiral angle is 10-30 degrees, and the guide roller is matched with a flexible coating layer, an electrostatic dissipation structure inside the roller body, and an encoder at the end of the shaft. It realizes the axial uniform dispersion of warp yarn, low-wear winding, stable tension control and electrostatic protection. The guide roller solves the problems of local accumulation of warp yarn, uneven tension, severe wear and electrostatic adsorption caused by traditional smooth guide rollers, significantly improving the warping quality and efficiency.

Description

Technical Field

[0001] This utility model relates to the field of textile machinery technology, specifically to a yarn leveling guide roller for a high-speed warping machine. Background Technology

[0002] Warping is a crucial pre-weaving process, and its quality directly determines the efficiency of subsequent weaving and the quality of the greige fabric. The warping machine guides hundreds to thousands of warp yarns drawn from the creel using guide rollers, ensuring they are wound parallel and evenly onto the warp beam.

[0003] In existing technologies, the commonly used guide rollers are smooth metal cylinders. While this structure doesn't present significant problems at low-speed warping, its inherent defects become apparent in the high-speed (800–1200 m / min) and high-density warping processes pursued in modern textile industry: vibrations are indeed prone to occur when the yarn moves on the smooth guide roller surface. This is because the yarn's running state is unstable due to various factors (such as slight imbalances in the guide roller and minor vibrations from the motor) during high-speed operation. Furthermore, the friction between the smooth guide roller surface and the yarn is relatively small, failing to provide sufficient lateral force to constrain the yarn's direction of movement.

[0004] Due to the lack of effective guidance and constraint, yarn tends to concentrate on the surface of the guide roller, meaning a large amount of yarn gathers in a localized area of ​​the guide roller instead of being evenly distributed along its entire axial length. This localized accumulation leads to uneven warp yarn density, causing tension fluctuations, affecting subsequent weaving quality, and increasing the risk of yarn breakage. Traditional smooth guide rollers result in localized warp yarn accumulation deviations of 20–30 mm and tension fluctuations of ±15%. Utility Model Content

[0005] The purpose of this invention is to overcome the defects in the existing technology and provide a yarn guide roller for a high-speed warping machine.

[0006] To achieve the above objectives, the technical solution of this utility model is to design a yarn-leveling guide roller for a high-speed warping machine, comprising a roller body and a rotating shaft coaxially fixedly connected to the roller body. The rotating shaft is mounted on the warping machine frame through a bearing seat. One end of the rotating shaft extends out of the bearing seat and is driven by a drive motor. The surface of the roller body is provided with spiral strip-shaped protrusions along the axial direction. The top of the spiral strip-shaped protrusions is an arc surface with a radius of 0.3-0.8 mm and a height of 0.2-0.5 mm. The helix angle of the spiral strip-shaped protrusions is 10-30 degrees.

[0007] Preferably, the spiral protrusions are multiple and evenly distributed along the axial direction of the roller.

[0008] The height and radius of the spiral protrusion are adapted to the warp diameter. The radius R (0.3–0.8 mm) and height h (0.2–0.5 mm) of the arc surface must match the warp diameter (typically 0.1–0.5 mm, for example, approximately 0.3 mm for polyester filament). If the radius of the arc surface is too small (<0.3 mm), the edge of the protrusion tip will be sharp, easily abrading the warp yarn; if it is too large (>0.8 mm), the guiding effect of the protrusion will be weakened (the warp yarn will easily slip past the top of the protrusion). Preferably, the radius of the arc surface is 0.5 mm, so that the contact between the warp yarn and the protrusion is a smooth arc transition, and the coefficient of friction is ≤0.15.

[0009] The height h needs to be slightly larger than the warp radius to ensure that the warp yarn can be embedded in the space between the protrusion and the roller body (forming a stable guide), but it should not be too large (otherwise the warp yarn will be excessively squeezed, causing a sudden change in tension). The height setting should ensure that it provides guidance while avoiding jamming.

[0010] The spiral protrusions and the roller surface are provided with a flexible coating layer. The flexible coating layer is made of elastic rubber / polyurethane (Shore hardness 40-60A), which buffers high-speed friction through flexible contact, reducing warp wear rate by 30%-50%, reducing breakage rate by 20%-40%, and improving winding tension uniformity (tension fluctuation range reduced from ±15% to within ±5%).

[0011] The surface of the flexible overlay is textured. The microtexture (such as a grid pattern or micro-dimples) of the flexible overlay enhances frictional stability and prevents yarn slippage.

[0012] The flexible coating layer has an oleophobic and hydrophobic coating on its surface. The oleophobic and hydrophobic coating (such as Teflon coating) reduces the adhesion of lint and dust, and, together with regular high-pressure airflow purging, achieves maintenance-free operation.

[0013] The roller body is equipped with a conductive fiber layer inside to conduct static electricity from the roller surface, and grounding electrodes connected to the conductive fiber layer are provided at both ends of the roller body. The static electricity generated by the friction between the warp yarn and the guide roller is conducted to the conductive fiber layer (carbon fiber bundle) through the flexible covering layer, and then introduced into the warping machine frame (grounding potential) through the grounding electrodes.

[0014] The conductive fiber layer consists of carbon fiber bundles uniformly distributed along the roller's axial direction, with one end in contact with the flexible covering layer and the other end connected to the grounding electrode. The uniform axial distribution of the carbon fiber bundles ensures effective discharge of static electricity from all areas of the roller surface. The grounding electrode (preferably a copper ring) is connected to the frame via a wire, ensuring that the electrostatic potential on the guide roller surface is ≤100V, reducing dust adsorption by more than 90%.

[0015] An encoder is installed at at least one end of the rotating shaft. The encoder monitors the rotational speed of the guide roller in real time and feeds the data back to the PLC controller. Combined with data from the tension sensor (installed on the warp path between the guide roller and the warp beam), the speed of the drive motor is dynamically adjusted to maintain warp tension fluctuation ≤ ±3%.

[0016] The advantages and beneficial effects of this utility model are as follows: 1. The flexible overlay layer possesses a certain degree of elasticity, which can buffer the impact force between the yarn and the guide roller to a certain extent, reducing the amplitude of yarn vibration. When the yarn contacts the guide roller and vibrates, the flexible overlay layer can absorb some energy through its own elastic deformation, making the yarn movement smoother. When the helical protrusions contact the yarn, they generate an axial force. As the yarn moves on the guide roller, due to the presence of the helical protrusions, the yarn is subjected to a force along the axis of the guide roller. This axial force, in conjunction with the tension on the yarn itself, pulls the yarn back to the correct position, preventing excessive yarn aggregation in local areas and achieving a uniform axial distribution of the yarn.

[0017] 2. As an elastic buffer layer, the flexible overlay not only cushions vibrations but also provides cushioning and protection between the yarn and the guide roller. When the yarn contacts the guide roller, the elastic deformation of the flexible overlay reduces rigid collisions between the yarn and the protrusions, minimizing yarn wear. Simultaneously, it ensures more uniform contact between the yarn and the guide roller, preventing excessive localized pressure that could damage the yarn. The friction between the flexible overlay and the yarn is greater than that between the yarn and the smooth surface of the guide roller. This greater friction prevents the yarn from slipping on the guide roller surface, ensuring stable movement as the guide roller rotates. When the yarn is subjected to an axial force, the greater friction ensures that the yarn moves in the intended direction, preventing slippage and ensuring uniform distribution. The micro-texture and oleophobic / hydrophobic coating on the surface of the flexible overlay further enhance the friction and anti-adhesion capabilities, contributing to stable yarn movement.

[0018] 3. The oleophobic and hydrophobic coating and the conductive fiber layer embedded inside the roller can reduce the adhesion of fuzz and dust, avoid sudden tension changes caused by the accumulation of impurities, and also improve the cleanliness of the warp yarn. Attached Figure Description

[0019] Figure 1 This is a schematic diagram of the structure of the guide roller of this utility model; Figure 2 This is a cross-sectional view of the roller body of this utility model.

[0020] In the diagram: 1. Roller body; 2. Shaft; 3. Bearing housing; 4. Drive motor; 5. Spiral strip protrusion; 6. Arc surface; 7. Conductive fiber layer; 8. Flexible coating layer; 9. Encoder. Detailed Implementation

[0021] The specific embodiments of this utility model will be further described below with reference to the accompanying drawings and examples. The following examples are only used to more clearly illustrate the technical solution of this utility model and should not be construed as limiting the scope of protection of this utility model.

[0022] according to Figures 1-2 As shown, this utility model is a yarn-leveling guide roller for a high-speed warping machine, including a roller body 1 and a rotating shaft 2 coaxially fixedly connected to the roller body 1. The rotating shaft 2 is mounted on the warping machine frame through a bearing seat 3. One end of the rotating shaft 2 extends out of the bearing seat 3 and is driven by a drive motor 4. The surface of the roller body 1 is provided with a spiral strip-shaped protrusion 5 along the axial direction. The top end of the spiral strip-shaped protrusion 5 is an arc surface 6. The radius of the arc surface 6 is 0.3-0.8 mm, the height is 0.2-0.5 mm, and the helix angle of the spiral strip-shaped protrusion 5 is 10-30 degrees.

[0023] Roller body 1 is a cylindrical hollow metal substrate (preferably made of 6061 aluminum alloy); rotating shaft 2 is coaxially fixedly connected to roller body 1 and mounted on warping machine frame through bearing seat 3, with one end extending out of bearing seat 3 and driven by drive motor 4; spiral strip-shaped protrusions 5 are continuously spirally distributed along the axial direction of roller body 1 (evenly spaced when there are multiple protrusions), with the top end being an arc surface 6, the radius of the arc surface 6 being R=0.3~0.8mm (preferably 0.5mm), the height being h=0.2~0.5mm (preferably 0.3mm), and the spiral helix angle α=10-30° (preferably 15°); The flexible covering layer 8 (made of polyurethane rubber with a Shore hardness of 40-60A, preferably 50A, and 1.5mm thick) is integrally formed with the roller body 1 and the spiral protrusions 5 through a hot vulcanization process, covering the protrusions but retaining a 0.2mm height difference (ensuring that the yarn preferentially contacts the soft arc surface 6). The surface is provided with micro-textures (micro-dimples 0.02mm deep, regularly arranged) and an oleophobic and hydrophobic coating (PTFE, 0.08mm thick). The elastic deformation of the flexible covering layer 8 allows the yarn to embed into the micro-textured pits, increasing the contact area; the oleophobic and hydrophobic coating (PTFE) further reduces the slippage tendency between the yarn and the covering layer. Compared with traditional guide rollers, the static friction between the yarn and the guide roller is increased by approximately 50%, effectively preventing slippage during high-speed operation.

[0024] Taking a guide roller with an outer diameter D=150mm, a length L=1700mm, and a helix angle α=15° as an example: The helix angle α (10-30°) of the spiral protrusion 5 is a key parameter for controlling the axial dispersion of the yarn. Its geometric relationship is as follows: Pitch (P): The distance between two adjacent spiral protrusions 5 along the axial direction of the guide roller, expressed by the formula P= Calculate (D is the outer diameter of the roller). For example, when D=150mm and α=15°, cot15°≈3.732, then P≈126mm.

[0025] Axial movement distance per turn (S): When the yarn rotates around roller 1 once, guided by the inclined surface of the helical angle, the theoretical axial movement distance is S=P⋅tanα. Substituting the data, we get S=126×tan15°≈126×0.268≈33.7mm (tan15°≈0.268).

[0026] Actual dispersion amount: Since the pitch P of adjacent spiral protrusions 5 is 126mm (the interval is relatively large), and the yarn wrap angle is usually 45°-60° (corresponding to about 1 / 8 to 1 / 6 of a rotation), the actual effective axial dispersion amount per turn is about 1 to 3mm (even distribution is achieved through the accumulation of multiple rotations).

[0027] The principle of vibration suppression is as follows: A flexible covering layer 8 covers the spiral protrusions 5 and the roller body 1 base. When the yarn vibrates, the covering layer absorbs the impact energy through elastic deformation (reducing the vibration amplitude by approximately 40%), reducing the risk of the yarn detaching from the guide roller surface due to vibration. The spiral protrusions 5 in this design are not primarily for absorbing vibration. Their main function is to guide and distribute the yarn. However, the flexible covering layer has a certain degree of elasticity, which can buffer the impact force between the yarn and the guide roller to some extent, reducing the amplitude of yarn vibration. When the yarn contacts the guide roller and vibrates, the flexible covering layer can absorb some energy through its own elastic deformation, making the yarn movement more stable.

[0028] The flexible overlay layer 8, acting as an elastic buffer layer, not only cushions vibrations but also provides cushioning and protection between the yarn and the guide roller. When the yarn contacts the guide roller, the elastic deformation of the flexible overlay layer 8 reduces rigid collisions between the yarn and the protrusions, minimizing yarn wear. Simultaneously, it ensures more uniform contact between the yarn and the guide roller, preventing excessive localized pressure that could damage the yarn. The friction between the flexible overlay layer 8 and the yarn is greater than that between the smooth guide roller surface and the yarn. This greater friction prevents the yarn from slipping on the guide roller surface, ensuring stable movement as the guide roller rotates. When the yarn is subjected to an axial force, the greater friction ensures that the yarn moves in the intended direction, preventing slippage and ensuring uniform distribution. Furthermore, the micro-textures (such as regularly arranged micro-dimples) and oleophobic / hydrophobic coatings (such as polytetrafluoroethylene, PTFE) on the surface of the flexible overlay layer 8 further enhance the friction and anti-adhesion capabilities of the yarn, contributing to stable yarn movement.

[0029] The principle of axial guidance is as follows: When the side of the helical protrusion 5 contacts the yarn, an axial force is generated. As the yarn moves on the guide roller, due to the presence of the helical protrusion 5, the yarn is subjected to a force along the axial direction of the guide roller. This axial force, in conjunction with the tension on the yarn itself, pulls the yarn back to the correct position, preventing excessive yarn aggregation in local areas. Specifically, the helix angle (10–30°) determines the inclination of the helical protrusion, thus affecting the magnitude and direction of the axial force. By rationally designing the helix angle, the yarn can gradually move to different positions along the axial direction as it passes over the guide roller, achieving a uniform distribution of the yarn along the axial direction of the guide roller.

[0030] The conductive fiber layer 7 consists of carbon fiber bundles (0.2 mm in diameter and 8 mm in spacing) uniformly distributed along the axial direction of the roller body 1. One end of the bundle is in contact with the flexible covering layer 8, and the other end is connected to the grounding electrode. The grounding electrode is a copper ring connected to the warping machine frame (grounding potential) via a wire. The static electricity (potential ≥ 1000 V) generated by the friction between the yarn and the guide roller is conducted through the flexible covering layer to the conductive fiber layer 7 (carbon fiber bundles with low resistivity), and then guided to the warping machine frame via the grounding electrode.

[0031] Encoder 9 is located at the right end of shaft 2, monitoring the guide roller speed in real time and feeding back to the PLC controller. Combined with a tension sensor (not shown in the figure) installed between the guide roller and the warp beam, it dynamically adjusts the speed of drive motor 4. When yarn tension fluctuates (e.g., due to changes in winding speed or localized accumulation), the tension sensor detects the signal and transmits it to the PLC controller. The controller adjusts the speed of drive motor 4 to match the guide roller's linear speed with the warp beam's winding speed, maintaining stable yarn tension. Combined with the axial dispersion effect of the spiral protrusions 5, this further ensures that the yarn is evenly wound onto the warp beam.

[0032] The bolts, nuts, screws, welding, etc. used to connect two or more parts in the above-mentioned fixing and installation are all known to those skilled in the art and will not be described in detail here. Similarly, the bearings required for components such as drive rollers are also known to those skilled in the art and will not be described in detail here either.

[0033] The above description is only a preferred embodiment of the present utility model. It should be noted that for those skilled in the art, several improvements and modifications can be made without departing from the technical principles of the present utility model, and these improvements and modifications should also be considered within the protection scope of the present utility model.

Claims

1. A yarn-leveling guide roller for a high-speed warping machine, comprising a roller body (1) and a rotating shaft (2) coaxially fixedly connected to the roller body (1), wherein the rotating shaft (2) is mounted on the warping machine frame via a bearing seat (3), and one end of the rotating shaft (2) extends out of the bearing seat (3) and is driven by a drive motor (4), characterized in that, The roller body (1) has a spiral strip-shaped protrusion (5) arranged along the axial direction on its surface. The top of the spiral strip-shaped protrusion (5) is a circular arc surface (6). The radius of the circular arc surface (6) is 0.3-0.8 mm and the height is 0.2-0.5 mm. The spiral helix angle of the spiral strip-shaped protrusion (5) is 10-30 degrees.

2. The yarn-leveling guide roller for a high-speed warping machine according to claim 1, characterized in that, The spiral protrusions (5) are multiple and are evenly distributed along the axial direction of the roller body (1).

3. The yarn-leveling guide roller for a high-speed warping machine according to claim 1, characterized in that, The height and radius of the spiral protrusion (5) are adapted to the diameter of the warp yarn.

4. A yarn-leveling guide roller for a high-speed warping machine according to claim 1, characterized in that, The spiral protrusions (5) and the roller body (1) are provided with a flexible coating layer (8).

5. A yarn-leveling guide roller for a high-speed warping machine according to claim 4, characterized in that, The surface of the flexible covering layer (8) is set with microtexture.

6. A yarn-leveling guide roller for a high-speed warping machine according to claim 4, characterized in that, The surface of the flexible coating layer (8) is provided with an oleophobic and hydrophobic coating.

7. A yarn-leveling guide roller for a high-speed warping machine according to claim 1, characterized in that, The roller body (1) is provided with a conductive fiber layer (7) for discharging static electricity from the surface of the roller body (1), and grounding electrodes connected to the conductive fiber layer (7) are provided at both ends of the roller body (1).

8. A yarn-leveling guide roller for a high-speed warping machine according to claim 7, characterized in that, The conductive fiber layer (7) is a bundle of carbon fibers uniformly distributed along the axial direction of the roller (1), with one end in contact with the flexible covering layer (8) and the other end connected to the grounding electrode.

9. A yarn-leveling guide roller for a high-speed warping machine according to claim 1, characterized in that, An encoder (9) is provided at least one end of the rotating shaft (2).

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