Adaptive Piecing Device for Ring Spinning Thread Breaks
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Solution Overview
Problem
Existing ring spinning machine systems are inefficient in handling thread breaks, as the process of finding and reconnecting the thread end is time-consuming and often unsuccessful, leading to reduced productivity and quality of the spinning process.
Innovation Solution
A method and device that automatically choose between two procedures for handling thread breaks: searching for and reconnecting the thread end (procedure a) for high-quality cop production or using an auxiliary thread (procedure b) for quicker production, depending on device utilization and success prospects, to optimize productivity and quality.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If the thread end is searched for and reconnected (procedure a), then the quality of cop production is improved, but the time required for piecing increases
Solution Approach 1:
The system dynamically switches between two piecing procedures based on real-time conditions. The control device monitors the spinning station status and selects procedure a) when high quality is prioritized and procedure b) when speed is prioritized, making the piecing process adaptive rather than static
Solution Approach 2:
The system changes the operational parameters of the piecing process by selecting different procedures with different time-quality trade-offs. The control device adjusts the piecing method based on current production needs, changing from thorough search-and-reconnect mode to auxiliary thread mode
2Manufacturing precision
If the thread end search procedure is always used, then the quality of cop production is improved, but the productivity of the ring spinning machine decreases
Solution Approach 1:
The system transitions from a static, one-size-fits-all piecing approach to a dynamic, condition-based selection system. The control device continuously monitors the spinning station and selects the appropriate procedure based on current demands, balancing quality and productivity
Solution Approach 2:
The system changes the operational parameters by selecting between two different piecing procedures. The control device adjusts the piecing method based on current production needs, switching between thorough search-and-reconnect mode and faster auxiliary thread mode
3Productivity
If the auxiliary thread procedure is always used, then the productivity of the ring spinning machine is improved, but the quality of cop production deteriorates
Solution Approach 1:
The system dynamically adapts the piecing method based on real-time conditions at the spinning station. The control device monitors station status and selects procedure a) when high quality is needed and procedure b) when speed is prioritized, making the process flexible rather than fixed
Solution Approach 2:
The system changes operational parameters by selecting between two procedures with different quality-speed trade-offs. The control device adjusts the piecing method based on current production demands, switching between quality-focused and speed-focused modes
4Reliability
If the piecing device is tied to one spinning station for thread break repair, then the thread break is repaired, but other spinning stations cannot be serviced
Solution Approach 1:
The piecing device is segmented into two independent operational modes: procedure a) for quality-critical repairs and procedure b) for speed-critical repairs. This segmentation allows the device to handle different types of repairs simultaneously or in sequence without being blocked by the time-consuming nature of any single procedure
Solution Approach 2:
The piecing device dynamically selects its operational mode based on the spinning station's needs and current workload. The control device monitors the state of multiple spinning stations and assigns appropriate procedures, enabling the device to serve multiple stations efficiently rather than being tied to a single station
Data Source
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AI summary
In a setting process of a setting device (2) on a ring spinning machine (1) with a plurality of spinning stations (13) at which a roving (6) emerges from delivery rollers (7) of a drafting unit (5) and is twisted into a thread (10) with a runner (9) and a rotating cop (11) and wound onto the cop (11), the setting device (2) automatically generates a setter in the event of thread breaks, in which a thread end (14, 14') is joined with the roving (6) emerging from the delivery rollers (7) and the spinning process is then continued.Alternatively, according to procedure a), the thread end (14) of the broken thread (10) is located, the found thread end (14) is grasped and used to start a cop (11) without thread break, or according to procedure b), an auxiliary thread (17) from a thread supply (16) is attached to the cop (11), this auxiliary thread (17) is then cut to obtain a thread end (14') attached to the cop (11), and this thread end (14') is used to start a cop (11) with a thread break. Depending on the workload of the starting device (2) and/or the expected success rate of procedure a), it is selected whether the thread end (14, 14') is provided according to procedure a) or b), assuming that procedure a) takes more time than procedure b).