Automatic Spindle Stopper for Yarn Machines
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Solution Overview
Problem
Current ring type yarn machines lack a system to detect yarn breakage, leading to idle spindle operation, production waste, increased breakages due to flying yarn, and the need for additional operators to manage breakages, resulting in reduced production efficiency and increased costs.
Innovation Solution
An automatic spindle stopper mechanism that includes a magnetic field coil assembly, spindle gripping mechanism, and locking mechanism, activated by breakage sensors to immediately stop the spindle upon yarn breakage, preventing further breakages and allowing for faster operation with fewer operators.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If the spindle continues revolving after yarn breakage, then the machine operates continuously, but yarn waste increases and secondary breakages occur
Solution Approach 1:
The system uses breakage sensors to detect yarn breakage and provides feedback to the control system, which automatically activates the spindle stopper to halt the spindle. This feedback mechanism prevents continuous operation after breakage, thereby reducing yarn waste and secondary breakages while maintaining productivity through rapid response.
Solution Approach 2:
The patent replaces manual detection and mechanical braking systems with an automated electromechanical system. Breakage sensors detect yarn breakage and trigger an electromagnetic spindle stopper, eliminating the need for manual operator intervention and providing faster, more consistent stopping that reduces yarn waste and secondary breakages.
2Device complexity
If manual spindle stopping is used, then the structure remains simple, but the response time is slow and production efficiency decreases
Solution Approach 1:
The system enables self-service operation where breakage sensors automatically detect yarn breakage and trigger the spindle stopper without requiring manual operator intervention. This automation reduces response time and improves production efficiency while maintaining relatively simple device structure through integrated sensor-actuator systems.
Solution Approach 2:
The spindle stopper mechanism is pre-positioned and ready to activate immediately upon detecting yarn breakage. The preliminary setup of the stopping mechanism allows for rapid response time, reducing the delay between breakage detection and spindle stopping, thereby minimizing production losses.
3Reliability
If the number of operators is increased to manage breakages, then breakage response improves, but labor costs increase
Solution Approach 1:
The automated breakage detection and spindle stopping system performs the breakage response function previously requiring human operators. The sensors and control system work autonomously to detect breakages and halt spindles, improving reliability of breakage response while eliminating the need for additional operators and reducing labor costs.
Solution Approach 2:
The patent replaces manual operator actions with an automated electromechanical system that detects and responds to yarn breakages. This substitution eliminates the need for additional human operators, reducing labor costs while maintaining or improving breakage response reliability through consistent sensor detection and automatic actuation.
4Device complexity
If spindle brakes are manually operated, then the mechanism remains simple, but production efficiency decreases due to manual intervention
Solution Approach 1:
The patent replaces manual mechanical brake operation with an automated electromechanical spindle stopper system. The breakage sensors trigger electromagnetic actuators that automatically apply braking force to the spindle, eliminating manual intervention and improving production efficiency while maintaining relatively simple mechanism through integrated sensor-actuator-brake systems.
Solution Approach 2:
The automated braking system uses feedback from breakage sensors to control the spindle stopper's activation. This feedback mechanism ensures the brake is applied precisely when needed, improving production efficiency by eliminating manual response delays while keeping the overall mechanism simple through automated control loops.
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 automatic spindle stopper reduces yarn waste, decreases the number of operators required, increases production efficiency, and lowers costs by promptly stopping the spindle upon yarn breakage and preventing secondary breakages, thereby enhancing overall machine performance.
Implementation Method 1
magnetic field coil assembly
Data Source
AI summary
A spindle stopping mechanism for a yarn machine including a magnetic field assembly which when energized by a signal from a yarn breakage sensor causes a spindle gripping mechanism to grip and stop a spindle. A locking mechanism is also provided.