Cross-wound Bobbin Density Control via Thread Tension Feedback
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Solution Overview
Problem
Existing cross-winding machines struggle to produce cross-wound bobbins with uniform density due to variations in thread tension and bobbin diameter across workstations, leading to inconsistent quality and productivity issues.
Innovation Solution
A method that compares the thread length and diameter of bobbins across workstations and adjusts the thread tension using a correction factor to ensure uniform density, achieved by integrating a thread tension control device with a central control unit that monitors and regulates thread tension based on density deviations from average values.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If rewinding is carried out at the highest possible winding speed to achieve high productivity, then productivity increases, but thread tension becomes uncontrollable and density uniformity deteriorates
Solution Approach 1:
The patent implements a feedback control system where the actual density of each cross-wound bobbin is measured and compared with the mean density of all bobbins. The workstation computer receives density values from all workstations, calculates deviations, and automatically adjusts thread tension parameters based on this feedback to correct density deviations in subsequent bobbins.
Solution Approach 2:
The system dynamically adjusts thread tension parameters during the winding process based on real-time density measurements. The thread tension control device modifies tension forces adaptively according to the calculated density deviations, allowing the system to maintain density uniformity even at high winding speeds where static control would fail.
2Manufacturing precision
If thread tension is increased to maintain density at high winding speeds, then density may be maintained, but thread tension control becomes difficult and quality consistency worsens
Solution Approach 1:
The system uses feedback from actual density measurements to automatically adjust thread tension parameters. Instead of manual intervention, the workstation computer calculates the required tension adjustments based on measured density deviations and sends control signals to the thread tension control device, making tension control automated and precise.
Solution Approach 2:
Each workstation system performs self-correction by automatically adjusting its own thread tension parameters based on its own density measurements and the collective data from other workstations. The system serves itself by identifying and correcting its own deviations without external intervention.
3Manufacturing precision
If manual monitoring and adjustment of thread tension is used, then some density control is achieved, but labor requirements increase and response time decreases
Solution Approach 1:
The system automatically monitors density, calculates deviations from the mean, and adjusts thread tension parameters without human intervention. The workstation computer continuously receives density data, processes it, and triggers automatic corrections, eliminating the need for manual monitoring and significantly reducing response time.
Solution Approach 2:
The automated feedback loop continuously monitors actual density values and immediately triggers corrective actions when deviations are detected. This real-time feedback system responds much faster than manual monitoring could achieve, as it eliminates human reaction time delays.
4Ease of operation
If thread tension is reduced to improve ease of operation, then operation becomes easier, but density control is lost and manufacturing precision deteriorates
Solution Approach 1:
The system maintains ease of operation with automated control while preventing density loss through continuous feedback monitoring. The workstation computer detects density deviations and automatically adjusts thread tension parameters to correct them, ensuring density control is maintained without requiring manual intervention.
Solution Approach 2:
The thread tension control device automatically maintains appropriate tension levels to ensure density control, eliminating the need for manual adjustment. The system self-regulates tension forces based on real-time density measurements, preventing density deterioration while maintaining operational simplicity.
Data Source
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AI summary
The invention relates to a method for optimizing the density of cross-wound bobbins (6) produced at workstations (4) of a cross-wound winding machine (1), wherein the workstations (4) are each equipped with a device (35) connected to a workstation computer (12) for detecting a thread length wound onto the cross-wound bobbin (6) and a device (36) for determining the diameter of the cross-wound bobbin (6), and have a thread tension control device with a thread tension sensor (22) and a thread tensioner (16).The method is characterized in that, when a cross-wound bobbin (6) is wound at a work station (4) of the cross-wound winding machine (1), upon reaching a predefinable thread length, the diameter of the cross-wound bobbin (6) is compared, or upon reaching a predetermined diameter of the cross-wound bobbin (6), the wound thread length is compared with corresponding values of cross-wound bobbins (6) wound at other work stations (4) of the cross-wound winding machine (1), and that if a limit value of a deviation of the value of this cross-wound bobbin (6) from the corresponding values of the cross-wound bobbins (6) wound at the other work stations of the cross-wound winding machine is exceeded, the thread tension control device of the work station (4) is adjusted based on a correction factor that results from the value of the deviation of this cross-wound bobbin (6).