Aluminum Heating Member Yarn Processor Temperature Control
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Solution Overview
Problem
Existing yarn processors using brass heating members are costly due to high mass requirements for heat capacity and suffer from low heat conductivity, leading to temperature variations and increased costs.
Innovation Solution
A yarn processor with a heating member made of aluminum, which maintains high heat capacity with lower mass and higher conductivity, allowing for efficient temperature control and cost reduction, and includes a controller to limit the heating member's temperature to 320 °C, along with a sensor and current control circuit to manage heat source usage and prevent overheating.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Stability of the object's composition
If brass is used as the heating member material to achieve high heat capacity, then temperature stability is improved, but mass increases leading to cost increase
Solution Approach 1:
The invention changes the material parameter from brass to aluminum, which has different thermal properties (lower specific heat but higher thermal conductivity). By controlling the temperature parameter to be equal to or less than 320°C, the system achieves temperature stability without requiring excessive mass, thus reducing cost while maintaining performance.
Solution Approach 2:
The heating member is constructed as a composite structure with an aluminum base material and a heat-resistant coating layer. This composite design allows the aluminum to provide high thermal conductivity and low mass, while the coating layer ensures temperature resistance and stability, resolving the contradiction between mass and temperature stability.
2Stability of the object's composition
If brass is used as the heating member material to achieve high heat capacity, then temperature variation suppression is improved, but cost increases
Solution Approach 1:
The invention changes the material parameter from brass to aluminum and controls the temperature parameter to be equal to or less than 320°C. This parameter change allows the use of cheaper aluminum material while maintaining temperature stability through the combination of aluminum's high thermal conductivity and controlled operating temperature.
Solution Approach 2:
The composite structure of aluminum base material with heat-resistant coating provides both cost reduction and temperature stability. The aluminum reduces material cost compared to brass, while the coating layer maintains temperature resistance, achieving cost reduction without sacrificing manufacturing performance.
3Weight of stationary object
If aluminum is used as the heating member material to reduce mass and cost, then cost is reduced, but temperature maintenance capability may worsen
Solution Approach 1:
The invention changes the material parameter to aluminum and simultaneously controls the temperature parameter to be equal to or less than 320°C. This dual parameter change allows aluminum's advantages (low mass, low cost) to be utilized while its temperature maintenance limitation is compensated by operating within aluminum's safe temperature range.
Solution Approach 2:
The composite structure with heat-resistant coating on aluminum base material enhances temperature maintenance capability. The coating layer protects the aluminum from excessive temperature exposure, allowing the system to maintain stable temperatures without requiring the aluminum to withstand extreme temperatures, thus preserving both low mass and temperature stability.
4Stability of the object's composition
If aluminum is used as the heating member material to achieve high thermal conductivity, then temperature uniformity is improved, but temperature control precision may worsen due to rapid heat transfer
Solution Approach 1:
The invention changes the material parameter to aluminum for high thermal conductivity and simultaneously controls the temperature parameter to be equal to or less than 320°C. This parameter combination allows rapid heat distribution for temperature uniformity while the controlled temperature range prevents excessive heat transfer that would compromise control precision.
Solution Approach 2:
The heat-resistant coating layer on the aluminum base material acts as a thermal barrier that moderates heat transfer. This allows the aluminum to provide temperature uniformity through high thermal conductivity while the coating layer prevents overly rapid heat transfer, maintaining temperature control precision within the controlled temperature range.
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
The use of aluminum heating members in the yarn processor reduces costs while maintaining high temperature uniformity along the yarn running direction, preventing yarn melting and adhering during breakage, and ensuring efficient power consumption and safety through controlled temperature management.
Implementation Method 1
a heat source of a resistance-heating type, which is configured to generate heat when an electric current runs in a heating wire such as a Nichrome wire
Implementation Method 2
a heating member configured to receive heat generated by the heat source and to heat the yarn contacted portion
Data Source
Figure 1
Figure 2
Figure 3
AI summary
An object of the present invention is to achieve cost reduction and to maintain high temperature of a heating member in the yarn running direction. A first heater 13 includes a heat source 51, a heating unit 52 heated by the heat source 51, and a controller 100 programmed to control the temperature of the heat source 51. The heating unit 52 includes: a yarn contacted portion 54 having a yarn contacted surface 56 which extends at least in a predetermined extending direction and with which a running yarn makes contact; and a heating member 53 configured to receive heat generated by the heat source 51 and to heat the yarn contacted portion 54. The heating member 53 is made of metal including aluminum, and the controller 100 is programmed to control the temperature of the heat source 51 so that the temperature of the heating member 53 is kept to be equal to or less than 320 °C.