Air Jet Spinning Station Automatic Piecing Mechanism
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Solution Overview
Problem
Air-jet spinning machines face significant productivity limitations due to frequent yarn defects and breaks, which require manual intervention by a service robot for piecing, leading to increased downtime and reduced efficiency.
Innovation Solution
The method involves using the spinning station's own equipment to manage yarn defects by sucking in the yarn end, separating it, and guiding it back through the vortex chamber counter to the spinning direction, allowing for autonomous piecing without the need for a service robot, thereby reducing downtime and increasing productivity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a service robot is used to perform piecing operations, then yarn defects can be removed and yarn can be reattached, but the spinning process is significantly impaired due to the robot needing to move to each spinning position sequentially
Solution Approach 1:
The spinning machine is equipped with automatic piecing devices including suction units, cutting units, and yarn guiding mechanisms that enable the machine to perform piecing operations autonomously without external robot intervention, thereby maintaining high productivity while ensuring yarn quality
Solution Approach 2:
The manual or robot-based mechanical piecing operation is replaced by an automated system using suction forces, mechanical cutting, and air flow guidance to retrieve and reattach yarn ends, eliminating the need for service robot intervention
2Ease of operation
If a service robot patrols along spinning positions to perform piecing, then yarn ends can be retrieved and reattached, but only one spinning position can be serviced at a time causing considerable limitations
Solution Approach 1:
The spinning machine is divided into multiple independent spinning positions, each equipped with its own automatic piecing devices, allowing simultaneous piecing operations at multiple positions without sequential robot intervention
Solution Approach 2:
Yarn ends are automatically retrieved and positioned in readiness before the actual piecing operation begins, using suction units and guiding mechanisms that prepare the yarn for immediate reattachment, thereby minimizing downtime
3Reliability
If the yarn end is allowed to detach naturally after yarn defect detection, then the defect can be removed, but the spinning process must be interrupted and manual intervention required
Solution Approach 1:
A yarn monitoring unit continuously detects yarn defects and provides feedback signals that automatically trigger the piecing sequence, including suction unit activation, cutting unit operation, and yarn guiding, enabling rapid defect removal without manual intervention
Solution Approach 2:
An air flow system acts as an intermediary to guide the detached yarn end through the vortex chamber and position it for reattachment, eliminating the need for direct mechanical handling and enabling continuous automated operation
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This approach enables simultaneous piecing across multiple spinning positions and immediate defect removal, significantly enhancing the productivity of air-jet spinning machines by eliminating the need for manual intervention and reducing waiting times for robot assistance.
Implementation Method 1
the yarn end is sucked in with the aid of a first suction unit of the spinning station in the area between an outlet opening of the turbulence chamber and the take-off device. The first suction unit is connected to a vacuum source
Implementation Method 2
an air flow acting counter to the spinning direction is generated for this purpose, which sucks the yarn end into the turbulence chamber via the outlet opening. The air flow is generated with the aid of one or more air injection nozzles
Data Source
Figure 1
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AI summary
The method involves interrupting the spinning process when a yarn fault is detected such that the yarn (4) detaches from the fiber strand (3) and a yarn end is formed. A piecing process is initiated subsequent to the interruption of the spinning process, in which the yarn end is suctioned with a suction unit (7) of a spinning station (2) in the area between an outlet opening (8) of a vortex chamber (1) and a withdrawal device (5). The yarn end and the end section of the fiber strand are jointly moved-in into the vortex chamber and the spinning process is resumed. An independent claim is included for an air jet spinning machine with a yarn store.