Cross-Wound Bobbin Slip Control via Adaptive Drum Acceleration
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Solution Overview
Problem
Existing methods for winding cross-wound bobbins struggle to maintain optimal slip for image disruption while minimizing energy consumption and being independent of winding parameters, leading to potential image windings and inefficient energy use.
Innovation Solution
A method that measures specific time periods within the image disruption cycle to determine a quotient representing slip, independent of other parameters, allowing for adjustment of the drive drum's acceleration phase based on this quotient compared to reference values, using control means to apply current to the motor for optimized slip and energy use.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the drive drum is accelerated and decelerated in recurring cycles to generate slip for image disruption, then image windings are prevented, but energy consumption increases
Solution Approach 1:
The drive drum's acceleration and deceleration phases are dynamically adjusted based on real-time slip measurement. The system transitions from static fixed-cycle control to dynamic adaptive control, where the motor torque and timing are continuously optimized to maintain effective slip while minimizing energy consumption during the image disruption process
Solution Approach 2:
A feedback control system is implemented where the actual slip between drive drum and cross-wound bobbin is continuously measured and used to adjust the acceleration and deceleration phases. The control unit modifies the motor current based on the measured slip to maintain optimal image disruption while reducing unnecessary energy expenditure, directly addressing the contradiction between reliability and energy use
2Reliability
If the slip is increased to ensure sufficient image disruption, then image windings are prevented, but energy consumption increases
Solution Approach 1:
The system dynamically changes the slip parameter based on measured conditions rather than maintaining a fixed high slip value. By adjusting the acceleration and deceleration phases according to real-time measurements, the system maintains the minimum necessary slip for effective image disruption while minimizing energy loss, transforming the approach from excessive parameter application to optimized parameter control
3Reliability
If the acceleration phase is extended to generate more slip, then image disruption is improved, but productivity decreases
Solution Approach 1:
The system employs periodic acceleration and deceleration cycles of the drive drum to generate the necessary slip for image disruption. These periodic actions are timed and controlled to achieve effective image disruption during specific phases while maintaining high productivity during other phases, creating a rhythm that balances quality and production speed
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
This approach enables automatic setting of desired slack for image disruption, reducing unnecessary energy consumption and improving winding quality by compensating for parameter dependencies, ensuring sufficient slip without excessive energy expenditure.
Implementation Method 1
The motor exerts a torque on the drive drum and thus causes the desired acceleration
Implementation Method 2
A recurring acceleration and deceleration of the drive drum results in a constantly changing slippage between the drive drum and the cross-wound bobbin
Data Source
AI summary
The method involves generating an alternating slip by acceleration and deceleration between a drive drum (3) and a cross-wound bobbin (2). The driving drum is formed with a spiraled groove (9). Maximum speed of the drive drum and rotational speed of the cross-wound bobbin are recorded according to two function portions. Ratio of two time periods is determined. An acceleration phase of the drive drum is adjusted according to comparison of quotient with a reference value. A braking power is applied in a motor (7) for delaying the drive drum. An independent claim is also included for a device for wrapping a cross-wound bobbin.