Adaptive Thread Guide for Flange Spool Winding
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Solution Overview
Problem
Existing spooling devices face challenges in achieving precise spooling of fine threads on flange spools, especially during high-speed operations, due to wear and misalignment issues, leading to uneven thread distribution and increased susceptibility to thread breakage.
Innovation Solution
A method and device that adapt the changing movement of the thread guide based on thread tension measurements to align with the flange spool geometry, adjusting the travel end position to ensure uniform winding by modifying the basic travel of the thread guide, thereby maintaining thread tension within defined limits.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If a changing thread guide is moved back and forth at high speed to achieve high productivity, then spooling speed increases, but thread tension control precision deteriorates leading to uneven winding
Solution Approach 1:
The patent implements a feedback control system where thread tension is continuously measured during the spooling operation and used to adjust the travel end position of the changing thread guide. The control device receives tension signals from a thread tension sensor and automatically modifies the thread guide's movement parameters to maintain uniform thread distribution, resolving the contradiction between high-speed operation and precise winding control.
Solution Approach 2:
The patent makes the thread guide's travel end position dynamically adjustable rather than fixed. The basic travel of the thread guide is modified in real-time based on measured thread tension, allowing the system to adapt to varying conditions during high-speed spooling and maintain manufacturing precision despite speed-related challenges.
2Manufacturing precision
If the thread guide travel end position is adjusted frequently to maintain precision, then winding quality improves, but control system complexity increases
Solution Approach 1:
The control device automatically adjusts the thread guide's travel end position based on feedback from the thread tension sensor without requiring external intervention. The system self-regulates by comparing measured tension against target values and autonomously modifying movement parameters, improving precision while keeping the control architecture relatively simple through automated decision-making.
3Duration of action of moving object
If flange spools are used for extended periods to maintain productivity, then operational duration increases, but spool alignment precision deteriorates due to wear
Solution Approach 1:
The thread tension sensor provides continuous feedback that detects variations caused by flange spool wear and misalignment. The control device uses this feedback to compensate for positioning errors by adjusting the thread guide's travel end position, allowing extended use of flange spools while maintaining winding precision despite degradation over time.
Data Source
AI summary
A method for adapting a travel end position of a changing movement of a thread to a flange spool includes means of which the thread is moved back and forth during a spooling operation along a rotation axis of the flange spool relative to the flange spool by means of a changing thread guide. The flange-side travel end position can be moved away from the flange of the flange spool in an axial direction when the thread tension decreases when the thread is moved away from the flange-side travel end position. Also, the flange-side travel end position can be moved by means of the changing thread guide in an axial direction towards a flange of the flange spool when the thread tension increases when the thread is moved away from the flange-side travel end position. Included is a spooling device for carrying out the disclosed method.