Battery Powered Level Wind System for Spinning Flyer

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Solution Overview

Problem

Existing spinning systems require users to manually change hooks or move guides to distribute fibrous roving evenly on bobbins, disrupting the spinning process and necessitating the use of special, expensive bobbins with complex gear systems.

Innovation Solution

A spinning flyer with a battery-powered level wind system that automatically moves a guide to distribute fibrous roving evenly on conventional bobbins, using a hollow level wind frame, level wind gear, and carriage system driven by an electric motor.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Extent of automation

If a mechanical level wind gear is used to automatically move the guide during spinning, then the guide can be automatically moved, but the system requires a complex set of gears including a special geared bobbin which increases device complexity and cost

Engineering Contradiction:

Improveautomatic guide movementVSAvoidcomplex gear system

Core Design Contradiction:

Extent of automationVSDevice complexity

Solution Approach 1:

The patent replaces the traditional mechanical gear system with an electric motor-driven system. The electric motor rotates the level wind frame, which carries the guide along its circumference, eliminating the need for complex mechanical gears and special geared bobbins while achieving automatic guide movement during spinning

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The level wind frame serves multiple functions: it acts as both the driving mechanism (replacing gears) and the guide carrier. By integrating the guide onto the level wind frame that rotates with the bobbin, the system achieves automatic level winding using a universal component that works with conventional bobbins without requiring special geared designs

Inventive Principle:

Principle #6Universality (Multi-functionality)

2Extent of automation

If special geared bobbins are used for mechanical level wind systems, then automatic level winding can be achieved, but the cost increases due to custom components

Engineering Contradiction:

Improveautomatic level windingVSAvoidcost of custom components

Core Design Contradiction:

Extent of automationVSEase of manufacture

Solution Approach 1:

The level wind frame is designed as a universal component that can be used with conventional bobbins. It carries multiple guides along its circumference and rotates synchronously with the bobbin, providing automatic level winding functionality without requiring any special or custom-made bobbins, thereby reducing manufacturing costs

Inventive Principle:

Principle #6Universality (Multi-functionality)

Solution Approach 2:

The electric motor-driven level wind frame replaces the mechanical gear system that required special geared bobbins. This substitution eliminates the need for expensive custom components while maintaining automatic level winding capability, making the system more cost-effective and easier to manufacture

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

3Device complexity

If manual hook changing is used to distribute roving on the bobbin, then the system can work with simple components, but the user must stop spinning to change hooks which reduces productivity

Engineering Contradiction:

Improvesimple componentsVSAvoidspinning continuity

Core Design Contradiction:

Device complexityVSProductivity

Solution Approach 1:

The level wind frame rotates continuously synchronously with the bobbin during the entire spinning process, carrying the guide along its path. This continuous rotation automatically distributes the roving evenly across the bobbin without requiring the user to stop spinning or manually change hooks, thereby maintaining uninterrupted productivity

Inventive Principle:

Principle #20Continuity of useful action

Solution Approach 2:

The guide is mounted on the level wind frame which rotates dynamically with the bobbin. As the frame rotates, the guide automatically moves to different positions around the bobbin, dynamically distributing the roving throughout the winding process without manual intervention, thus maintaining spinning continuity

Inventive Principle:

Principle #15Dynamics

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 continuous spinning without manual intervention, allowing for even distribution of fibrous roving on conventional bobbins, reducing costs by eliminating the need for special bobbins and complex gear systems.

Implementation Method 1

A battery contained in the flyer powers the electric motor

Methodology Applied

Scientific EffectBattery (electricity): Battery (electricity)

Data Source

PatentUS12281415B2Battery powered level wind system for spinning and processing fiber for yarn

Publication Date: 2025.04.22 FORD RICHARD

AI summary

A flyer for spinning a fibrous roving onto a bobbin includes a housing defines a central hole passing therethrough. A center rod, supporting the bobbin, is rotated by a spinning system. A battery is contained in the flyer and powers an electric motor. A hollow level wind frame is affixed to the housing and defines an elongated slot passing therethrough. A level wind gear in the level wind frame is rotated by the electric motor. A level wind carriage system is driven by the level wind gear and oscillates repeatedly between a first end and a second end as the level wind gear is rotated, and includes a pawl engaged with the level wind gear. A guide is coupled to the pawl and passes through the elongated slot defined by the level wind frame. The fibrous roving passes through the guide.