Ball Winding Color Control via Chromatic Detection
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Solution Overview
Problem
Current ball winding machines cannot precisely control or program the initial and final colors of a ball of thread with multiple color stretches, leading to uncertainty and inefficiency in producing identical textile products, resulting in material waste.
Innovation Solution
A control and programming system for ball winding machines that includes a chromatic characteristic acquisition device, a thread movement system using compressed air, and a cutting mechanism, allowing for precise determination and control of the initial and final colors by learning the selected color and activating the cutting device at the appropriate interval.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If prior art ball winding machines are used, then the winding process can be completed, but the initial and final colors of the ball cannot be precisely controlled or determined
Solution Approach 1:
The system performs preliminary learning of the color sequence pattern before actual ball production. The control unit stores the identified color sequence and uses it to predeterminedly control the winding process, ensuring the ball starts and ends with the same color without requiring real-time adjustment during winding.
Solution Approach 2:
The system uses a detection device to acquire chromatic characteristics of the thread and provides feedback to the control unit. This feedback loop enables the system to identify the color sequence pattern and adjust the winding process to achieve predetermined initial and final colors.
2Productivity
If prior art systems are used, then ball production can proceed, but material waste is generated due to inability to produce identical products
Solution Approach 1:
The system predeterminedly programs the color sequence pattern before production. By knowing in advance which colors will be at the beginning and end of the ball, the system eliminates the need to discard balls that don't meet color specifications, thereby reducing material waste while maintaining production efficiency.
3Ease of operation
If prior art systems are used, then the winding process can be completed, but uncertainty exists in processing for the final user
Solution Approach 1:
The detection device continuously monitors the chromatic characteristics of the thread and provides feedback to the control unit. This real-time information feedback eliminates uncertainty by providing precise knowledge of the color sequence, enabling the final user to process balls with confidence that they will be identical.
4Measurement precision
If a chromatic characteristic acquisition device is added, then color control is improved, but device complexity increases
Solution Approach 1:
The control unit serves multiple functions: it controls the winding machine operation, processes chromatic data from the detection device, identifies color sequence patterns, and predeterminedly programs the ball production. By making the control unit multi-functional, the system achieves precise color control without proportionally increasing overall system complexity.
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
Enables the production of balls with predetermined initial and final colors, ensuring consistency and reducing material waste by systematically controlling the winding process.
Implementation Method 1
a device for acquiring the chromatic characteristics of the various stretches of thread
Implementation Method 2
The device for moving the thread comprises a nozzle fed with compressed air
Data Source
Figure 1~2
Figure 3~4
AI summary
Described is a control and programming system 1 and method for producing a ball of thread 10 having a plurality of stretches with different colours "a", "b", "c" along the longitudinal direction with a ball winding machine comprising: a device 2 for acquiring the chromatic characteristics "a", "b", "c" of the thread 10 connected to a respective control unit, a device 3 for moving the thread 10 towards the ball winding machine and a device 4 for cutting the thread 10.