Air Spinning Machine Yarn Quality Control via Sensor Feedback
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Solution Overview
Problem
Air-jet spinning machines face issues with contamination and quality deterioration due to deposits on the yarn-forming elements and spinnerets, requiring frequent manual cleaning and inefficient additive application, which affects yarn quality and production efficiency.
Innovation Solution
Implementing a sensor system to monitor physical parameters of the yarn, such as hairiness, mass, and thickness, to quantify and qualify the additive application, allowing for real-time adjustment of additive supply to maintain optimal yarn properties and facilitate automatic cleaning without machine stoppage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If manual cleaning of the spinneret and yarn-forming element is performed periodically, then the deposits can be removed, but machine stoppage and loss of production time occur
Solution Approach 1:
The system performs automatic cleaning of the spinneret and yarn-forming element using a cleaning agent supplied through the additive supply device, eliminating the need for manual cleaning operations and continuous machine stoppage while maintaining yarn quality consistency
Solution Approach 2:
The cleaning operation is integrated into the continuous operation of the air-jet spinning machine, allowing the spinneret to be cleaned without stopping production. The additive supply device continuously or periodically delivers cleaning agents to maintain optimal conditions throughout operation
2Manufacturing precision
If additive is applied to improve yarn properties, then yarn quality improves, but contamination and deposits form on the spinneret and yarn-forming element
Solution Approach 1:
A sensor system monitors physical parameters of the yarn (such as hairiness, mass, thickness) to detect additive application status and yarn quality in real-time, providing feedback to control the additive supply device to optimize the balance between improving yarn properties and minimizing deposits
Solution Approach 2:
The system changes the physical or chemical parameters of the additive (concentration, flow rate, application timing) based on monitored yarn properties, adjusting the additive supply to achieve optimal yarn quality while reducing contamination and deposit formation on the spinneret and yarn-forming element
3Manufacturing precision
If frequent cleaning operations are performed, then yarn quality is maintained, but production efficiency decreases
Solution Approach 1:
The cleaning operation is integrated into the continuous operation of the air-jet spinning machine, allowing the spinneret to be cleaned without stopping production. The additive supply device continuously or periodically delivers cleaning agents to maintain optimal conditions throughout operation
Solution Approach 2:
The system performs automatic cleaning of the spinneret and yarn-forming element using a cleaning agent supplied through the additive supply device, eliminating the need for manual cleaning operations and continuous machine stoppage while maintaining yarn quality consistency
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
Ensures consistent yarn quality by precisely controlling additive application, reducing manual maintenance, and enhancing production efficiency by preventing substandard yarn production and improving yarn properties like hairiness and strength.
Implementation Method 1
the yarn leaving the outlet of the spinneret is monitored with the aid of a sensor with regard to at least one physical parameter, which is determined on the basis of at least one measured value supplied by the sensor
Implementation Method 2
the spinning position is at least temporarily supplied with an additive during operation of the air-jet spinning machine with the aid of an additive supply and onto the fiber structure and/or the yarn or is applied to parts of the spinneret
Implementation Method 3
the outer fibers of the fiber structure are wound around the inner core fibers with the help of a turbulent air flow generated by the air nozzles inside the turbulence chamber in the area of an inlet opening of the yarn-forming element
Data Source
Figure 1
Figure 2
Figure 3a~3c
AI summary
The invention relates to a method for operating an air spinning machine, wherein the air spinning machine has at least one spinning station with a spinneret (2) for producing a yarn (6), wherein a fiber assembly (3) is supplied to the spinneret (2) via an inlet (4) during operation of the spinning station, wherein the fiber assembly (3) is rotated within a vortex chamber (5) of the spinneret (2) by means of a vortex airflow, so that a yarn (6) is formed from the fiber assembly (3), which finally leaves the spinneret (2) via an outlet (7), and wherein an additive (9) is supplied to the spinning station at least temporarily during operation of the air spinning machine by means of an additive supply (8) and is applied to the fiber assembly (3) or to parts of the spinneret and/or the yarn (6).According to the invention, it is proposed that the yarn (6) leaving the outlet (7) is monitored with regard to at least one physical parameter by means of a sensor (11), whereby, based on at least one measured value supplied by the sensor (11) and correlating with the said parameter, it is determined whether and/or how much additive (9) has been applied to the fiber composite (3) or to the yarn (6) produced therefrom and passing through the sensor (11). Furthermore, an air-jet spinning machine is proposed for carrying out the method.